Documente Academic
Documente Profesional
Documente Cultură
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Note
♦ The term 'checking' includes all necessary subsequent work such as adjusting, readjusting, correcting and
topping up, but does not include repairing, replacing and reconditioning parts or assemblies!
OK 1) Not OK 2)
Check conformity of vehicle Ident. No. on vehicle, data bank, vehicle registration
documents and on-board literature
→ Checking Vehicle Ident. No. for conformity [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Checking Vehicle Ident. No. for conformity [9PAAJ1]
Removing transport locks, transport protection
→ Removing transport protection [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→
Removing transport protection [9PAAJ1]
→ Main switch for power supply (removing battery disconnect switch) [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Main switch for power supply (removing
battery disconnect switch) [9PAAJ1]
Battery: check battery charging condition (bear in mind transport and idle period)
file://E:\POSES\data\rl\2\9PA\010100_1.htm 5/19/2011
Sales check Page 3 of 4
file://E:\POSES\data\rl\2\9PA\010100_1.htm 5/19/2011
Sales check Page 4 of 4
Foot and parking brakes, clutch, steering, automatic speed control, ParkAssist,
heating, air-conditioning system and instruments: check operation
→ Test drive: sales check
Transmission: check operation
Check vehicle for unusual handling behaviour, vibration and noise
Diagnosis system: read out and erase fault memory
→ Diagnosis system: Reading out fault memory and activating systems [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Diagnosis system: Reading out fault memory
and activating systems [9PAAJ1]
1) OK = functioning correctly
2) Not OK = not functioning correctly
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\010100_1.htm 5/19/2011
Battery: checking charging condition Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Note
Follow the instructions for the Tester, topic: charge state/functional state.
2. Connect battery tester to vehicle battery and check the battery charge state according to the operating
instructions for the tester. Rapid-start battery charger 44
file://E:\POSES\data\rl\2\9PA\010101_0.htm 5/19/2011
Battery: checking charging condition Page 3 of 3
– 2. Charge state OK
– 1. Charge state: 80 - 50 %
– 2. Battery charge state reduced, recharge battery and observe an inactive period for two hours after charging.
→ 2706 Battery
– 1. Charge state: 50 - 10 %
– 2. Battery flat; recharge battery and observe an inactive period for two hours after charging. → General
information and on vehicle battery [9PAAE1 9PAAE7 9PAAF1]→ General information and on vehicle
battery [9PAAD1 9PAAD7]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\010101_0.htm 5/19/2011
Alarm system: Checking operation of indicators Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Checking indicators
Vehicle must be unlocked and the sales check item - Diagnosis system: systems activated and fault memory read
out - must be performed.
1. Lock vehicle with the remote control. Shortly after locking, no warning tone must be emitted by the alarm
system horn. If a warning tone is emitted, check exterior covers, glove compartment cover, centre console
cover and all doors; open and close these items in turn.
2. As soon as the vehicle is locked, the LED - in the middle of the driver's door trim panel - must flash quickly
for 2 seconds and then flash slowly.
Fault display:
3. LED flashes quickly for 2 seconds, lights up for 28 seconds and then flashes slowly >> connect the System
Tester and read out the fault memory. → "Rep. Gr. 96 Alarm system diagnosis manual "
Vehicle must be unlocked and the sales check item - Diagnosis system: systems activated and fault memory read
out - must be performed.
1. Lock vehicle with the remote control. Shortly after locking, no warning tone must be emitted by the alarm
system horn. If a warning tone is emitted, check exterior covers, glove compartment cover, centre console
cover and all doors; open and close these items in turn.
2. As soon as the vehicle is locked, the LED - in the middle of the driver's door trim panel - must flash quickly
for 2 seconds and then flash slowly.
Fault display:
3. LED flashes quickly for 2 seconds, lights up for 28 seconds and then flashes slowly >> connect the System
Tester and read out the fault memory. → "Rep. Gr. 96 Alarm system diagnosis manual "
file://E:\POSES\data\rl\2\9PA\010101_1.htm 5/19/2011
Alarm system: Checking operation of indicators Page 3 of 3
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\010101_1.htm 5/19/2011
Sales check: Fitting mobile phone console Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
E-box
Note
The E-box components are not included in the mobile phone console delivery package.
If the customer already has an E-box, this can be installed on the mobile phone console.
If the customer does not yet have an E-box, an E-box that can be used with the mobile phone to be fitted
must be purchased on the open market.
Overview of E-box
file://E:\POSES\data\rl\2\9PA\010123_0.htm 5/19/2011
Sales check: Fitting mobile phone console Page 3 of 7
Note
An assembly kit for the mobile phone console is supplied in the vehicle along with the I No. for the mobile
phone console.
Before delivery to the customer, this console must be fitted with whichever E-box matches the customer's
mobile phone.
The E-box to be fitted must be agreed with the customer and purchased on the open market, if required.
Installation Location:
file://E:\POSES\data\rl\2\9PA\010123_0.htm 5/19/2011
Sales check: Fitting mobile phone console Page 4 of 7
1. On the upper part -E- , mark the fixing variant of the relevant
interface box, drill as required, push the wiring through and position
correctly using the fastening screws -1- .
file://E:\POSES\data\rl\2\9PA\010123_0.htm 5/19/2011
Sales check: Fitting mobile phone console Page 5 of 7
Assembly C, D, E
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Sales check: Fitting mobile phone console Page 6 of 7
10. Screw in the fastening screws -1- for the interface box support into
the upper part -E- . → Tightening torque: 0.4 ftlb.
file://E:\POSES\data\rl\2\9PA\010123_0.htm 5/19/2011
Sales check: Fitting mobile phone console Page 7 of 7
14. Connect wiring for the VDA interface and antenna leads
G - Centre console
F - Seat
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\010123_0.htm 5/19/2011
Diagnostic system: reading out fault memory and activating systems Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
WARNING
Sudden voltage interruption of the power supply to the control unit.
Risk of irreparable damage to the control unit.
→ During vehicle handover, it is essential to guarantee the power supply for the Porsche System Tester. A
battery charger with a current rating of at least 40 A must be connected to the external power supply.
1. PIWIS Tester 9718 must be connected to the vehicle, then start the System Tester. Switch on ignition.
Press >> to continue.
3. In the Special functions menu, select Cayenne handover and continue with >> .
4. Follow the instructions on the Tester (vehicle handover). Press >> to continue.
file://E:\POSES\data\rl\2\9PA\0101IN_0.htm 5/19/2011
Diagnostic system: reading out fault memory and activating systems Page 3 of 5
6. The Tester runs the functions and displays the confirmation message Functions ended. Press >> to
continue.
7. Enter Vehicle Ident. No. and press >> . Compare Vehicle Ident. No. and if it is OK, confirm with F7 .
8. Exit the Special functions menu and select the Cayenne menu.
10. Read out the fault memory and then erase the fault memory for all control units for which a fault was
recorded.
11. For vehicles with the navigation system, insert the navigation DVD into the navigation unit (DVD) under the
passenger’s seat and switch on PCM.
11.1. Switch on the PCM in clear surroundings (to load GPS almanac). The almanac is loaded as soon as four
satellites are identified.
11.2. Message on PCM >>Loading navigation DVD<< - do not interrupt loading operation.
12. Print out vehicle handover log and place it in vehicle documents folder.
13. Test-drive the vehicle and read out the fault memory. Check faults in accordance with diagnosis if necessary
and erase fault memory before delivering the vehicle.
Activating systems
Note
The work procedure is menu-driven; the Tester instructions have the highest priority, additional operation is
specified using the arrow icons, e.g. >> .
1. Connect the Porsche System Tester to the vehicle and start the
System Tester. Switch on ignition. Press >> to continue.
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Diagnostic system: reading out fault memory and activating systems Page 4 of 5
Porsche System Tester connected to vehicle and System Tester started. Ignition switched on.
Note
All control units are automatically read out in turn.
2. Faulty control units are flagged as such with an asterisk before their name >> * DME.
3. Select these control units, then select Read out fault memory.
4. Fault memory can now be deleted in the Erase fault memory menu. If PCM is installed, continue with Load
navigation .
The fault memory must be read out again or erased after the test drive. If the same faults are present again,
proceed in accordance with Rep.-Gr. 20 — 97 Diagnosis Manual.
Loading navigation
Note
Only vehicles with PCM.
2. Navigation CD is loaded.
The PIWIS Tester 9718 is connected to the vehicle via a diagnostic socket. The diagnosis socket is located inside
the vehicle in the vicinity of the driver's A-pillar below the instrument panel.
1. Open the cover of the diagnostic socket and plug in the plug
connection for the PIWIS Tester.
2. Start the PIWIS Tester 9718 and follow the instructions on the
Tester.
3. Select vehicle type, press >> and start the automatic control unit
search.
4. If an asterisk appears in front of the relevant control unit, read out the
fault memory and follow the instructions on the Tester.
Note
As of model year '06, voice recognition will be offered as additional equipment.
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Diagnostic system: reading out fault memory and activating systems Page 5 of 5
After vehicle handover is done with the PIWIS tester, voice recognition is active in German.
2. After the voice recognition CD is read, Select language appears on the PCM screen.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\0101IN_0.htm 5/19/2011
Checking Vehicle Ident. No. for conformity Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The adhesive label for the on-board literature is located on the data bank affixed to the rear left of luggage
compartment.
Check whether the following vehicle identification numbers are identical, and then affix the enclosed data-bank
adhesive label to the on-board literature (guarantee and maintenance booklet).
– Vehicle Ident. No. stamped on bodyshell, in the rear right of luggage compartment
– Vehicle Ident. No. on the data-bank adhesive label in rear left of luggage compartment.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\3087443_KDNum_0.htm 5/19/2011
Removing transport protection Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
– 1. Material: Fleece
– 1. Material: Fleece
file://E:\POSES\data\rl\2\9PA\3087473_KDNum_0.htm 5/19/2011
Removing transport protection Page 3 of 3
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\3087473_KDNum_0.htm 5/19/2011
Checking lid and doors Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
– Check whether the return spring on the upper part of the lock pulls back the safety hook as far as the stop.
– Check tank cap is locked by the tank cap lock in the closed position.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\3087503_KDNum_0.htm 5/19/2011
Mobile roofs: Checking operation Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
2. Fully open and close sliding roof lining by hand. During operation, check for noise and stiffness.
Note
When the maximum duration of operation (> 40 s) is exceeded, the fault code 0409 can be stored in the
control module.
Initialisation must be completed fully as otherwise the roof cannot be operated electrically.
1. Turn on ignition and turn rotary switch to the position "Close roof fully".
3. Keep the rotary switch pressed until the sun blind and the roof are completed closed.
4. Relieve the seals from strain by briefly opening and then closing the roof again.
5. Read out the fault memory with the Porsche System Tester and remedy any faults.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\3087533_KDNum_0.htm 5/19/2011
Checking exterior equipment and paintwork Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The following items can be checked by simple visual inspection, no assembly work required.
1. Check whether transport protection has been completely removed and ensure that no film remains in the
body joints or under seals.
2. Check underbody for noticeable areas where undersealing material is missing (e.g. scrapes).
3. Check lower side member of body flange for deformation of jacking points.
4. Check outer shell of vehicle for noticeable soiling by cavity sealing wax.
Checking paintwork
1. Check outer shell of vehicle for noticeable sheetmetal damage such as dents and bulges.
2. Check painted surfaces of vehicle for noticeable defects such as scores, scratches, notches, scrapes, pores,
bubbles or signs that the bodywork is coming through the paint.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\3087563_KDNum_0.htm 5/19/2011
Checking glazing Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Check glazing
Note
The following items can be checked by simple visual inspection, no assembly work required.
1. Check whether transport protection has been completely removed and ensure that no film remains in the
body joints or under seals.
3. Check surrounds and rubber sections of vehicle glazing for damage and cracks.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\3087594_KDNum_0.htm 5/19/2011
Checking vehicle equipment for completeness Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
file://E:\POSES\data\rl\2\9PA\3087624_KDNum_0.htm 5/19/2011
Checking vehicle equipment for completeness Page 3 of 4
1) Except for German-speaking countries, the on-board information folder containing technical information (Driver's Manual and Guarantee and
Maintenance booklet) must be supplied by the dealer or importer.
2) The PCM/CDR manual must be supplied by the dealer or importer in all non-German-speaking countries.
3) The navigation CD must be supplied by the dealer or importer in the U.S.
4) Only in USA states that require a number plate at the front of the vehicle → 668323 Installing number plate trim [9PAAD1 9PAAD7 9PAAE1
9PAAE7]→ 668323 Installing number plate trim [9PAAF1].
5) Replace the one-way wiper blades with the enclosed wiper blades → 922719 Removing and installing wiper blade.
Tools
Vehicle key
1)
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Checking vehicle equipment for completeness Page 4 of 4
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Interior trim: visual inspection for damage and soiling Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The following items can be checked by simple visual inspection, no assembly work required.
1. Check whether transport protection has been completely removed and ensure that no film remains in the
component joints or under seals.
2. Check interior equipment of vehicle for noticeable damage such as scores, scratches, notches and scrapes.
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.
Condition inspection
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Interior trim: visual inspection for damage and soiling Page 3 of 3
If it displays evidence of damage in the form of cuts, fraying, seam tears etc., the seat belt must be replaced.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Test drive - sales check Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The following test items are included in the test drive.
– Activate cruise control during the test drive and check operation.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Mobile roofs: checking operation Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
WARNING
Danger of injury! Risk of material damage!
→ Do not reach into the moving area of the mechanism when opening and closing the roof assembly.
→ Anti-crushing protection is deactivated in emergency operation mode.
→ If there is danger, release the rotary switch immediately or activate it in the opposite direction, or switch off
the ignition.
→ Never open the roof assembly without having initialised the limit position of the motors. Danger of collision
for the two rear roof segments!
Note
When the maximum duration of operation (> 40 seconds) is exceeded, the fault code 0409 (Rotary switch
emergency button signal is permanently displayed) can be stored in the control unit.
Initialisation must be completed fully as otherwise the roof cannot be operated electrically.
1. Switch on ignition and turn rotary switch to the position "Close roof fully". Wait until the roof remains in any
position.
2. Hold the rotary switch in this position -arrow- . The closing operation starts after approx. 5 seconds. Keep
the rotary switch pressed until the sun blind and the roof are closed. First the sun blind is closed; then the lid
of the roof assembly is closed, opened briefly, and closed again. The rear lid of the roof assembly closes
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Mobile roofs: checking operation Page 3 of 3
3. Relieve the seals from strain by briefly opening and then closing the roof again.
4. Read out the fault memory with the Porsche System Tester and remedy any faults.
Checking operation
2. In vehicles with a sunroof: Fully open and close sliding roof lining by hand. During operation, check for
noises and stiffness.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\4623558_KDNum_0.htm 5/19/2011
Minor maintenance Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Minor maintenance
Note
The engine oil and oil filter must be changed every 10,000 km (6,000 mls) in vehicles which are operated in
countries where leaded fuel is used.
If the mileage for scheduled maintenance is not reached, minor maintenance must be carried out after 2, 6,
10...... years.
The terms "inspect" and "check" include all necessary subsequent work such as adjustments, readjustments,
corrections and replenishment. They do not include the repair, replacement or overhaul of components or
assemblies.
The maintenance item > Replacing spark plugs < depends on the engine type. Please refer to the "Additional
maintenance" chapter → 287055 Replacing spark plugs.
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Minor maintenance Page 3 of 3
Brake hoses and lines: visual inspection for damage, routing and corrosion → Running gear
maintenance: visual inspection - brake lines/brake pads/brake discs
Drive shafts: visual inspection of boots for leaks and damage → Running gear maintenance: axle
joints/drive shafts
Front cardan shaft: visual inspection of air bellows for damage (up to and including '03 model) →
Cardan shaft maintenance
Rear cardan shaft: visual inspection of centre bearing for damage (up to and including '03 model) →
Cardan shaft maintenance
Check threaded connections of suspension adjustment system at front and rear are secure (applies
to the first service only) → Cardan shaft maintenance
Exterior of tyres and spare wheel: check condition and tyre pressure → Running gear maintenance:
tyres and spare wheel - checking condition and tyre pressure
Panorama roof system: teach control unit → Panorama roof system control unit
Windscreen wiper/washer system, headlight washer: checking operation, fluid level and nozzle
settings, pay attention to antifreeze protection in winter months; check wiper blades → Electrics
maintenance: windscreen wiper and washer system, ...
All headlights: check adjustment. Horn: checking operation → Electrics maintenance: checking
operation of vehicle lights
Battery and vent hose: check condition → Battery maintenance: checking condition of battery and
vent hose
Test drive:
remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering,
transmission, ParkAssist, automatic speed control, PSM switch, heating, air-conditioning system and
instruments: check operation → Test drive - maintenance
Oils, fluids: visual inspection for leaks
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Minor maintenance Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Minor maintenance
Note
The engine oil and oil filter must be changed every 10,000 km (6,000 mls) in vehicles which are operated in
countries where leaded fuel is used.
If the mileage for scheduled maintenance is not reached, minor maintenance must be carried out after 2, 6,
10...... years.
The terms "inspect" and "check" include all necessary subsequent work such as adjustments, readjustments,
corrections and replenishment. They do not include the repair, replacement or overhaul of components or
assemblies.
The maintenance item > Replacing spark plugs < depends on the engine type. Please refer to the "Additional
maintenance" chapter → 287055 Replacing spark plugs [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ 287055
Replacing spark plugs [9PAAD1 9PAAD7].
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Minor maintenance Page 3 of 3
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Major maintenance Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Major maintenance
Note
The engine oil and oil filter must be changed every 10,000 km (6,000 mls) in vehicles which are operated in
countries where leaded fuel is used.
If the mileage for scheduled maintenance is not reached, major maintenance must be carried out after 4, 8,
12...... years.
The terms "inspect" and "check" include all necessary subsequent work such as adjustments, readjustments,
corrections and replenishment. They do not include the repair, replacement or overhaul of components or
assemblies.
The maintenance item > Replacing spark plugs < depends on the engine type. Please refer to the "Additional
maintenance" chapter → 287055 Replacing spark plugs.
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Major maintenance Page 3 of 3
shafts
Power steering: check fluid level → Running gear maintenance: steering gear - fluid level...
Fuel lines and connections: visual inspection
Radiators and air inlets: visual inspection for external contamination and blockage; Coolant: check
the level and antifreeze protection → 190101 Checking cooling system
Foot-operated parking brake: check free play → Running gear maintenance: checking free play of
foot-operated parking brake
Brake system: visual inspection of brake pads and brake discs for wear → Running gear
maintenance: visual inspection - brake lines/brake pads/brake discs
Brake hoses and lines: visual inspection for damage, routing and corrosion → Running gear
maintenance: visual inspection - brake lines/brake pads/brake discs
Drive shafts: visual inspection of boots for leaks and damage → Running gear maintenance: axle
joints/drive shafts
Front cardan shaft: visual inspection of air bellows for damage (up to and including '03 model) →
Cardan shaft maintenance
Rear cardan shaft: visual inspection of centre bearing for damage (up to and including '03 model) →
Cardan shaft maintenance
Axle joints: check the play and visually inspect the dust bellows for damage → Running gear
maintenance: axle joints/drive shafts
Exhaust system: visual inspection for leaks and damage, check mounts
Exterior of tyres and spare wheel: check condition and tyre pressure → Running gear maintenance:
tyres and spare wheel - checking condition and tyre pressure
Lubricate door arrester and fastening pins → Checking lid and doors
Panorama roof system: teach control unit → Panorama roof system control unit
Windscreen wiper/washer system, headlight washer: check operation, fluid level and nozzle settings,
pay attention to antifreeze protection in winter months; check wiper blades → Electrics maintenance:
windscreen wiper and washer system, ...
Seat belts: checking operation and condition → Checking seat belts
All headlights: check adjustment; horn: check operation → Electrics maintenance: checking
operation of vehicle lights
Battery and vent hose: check condition → Battery maintenance: checking condition of battery and
vent hose
Trailer hitch: check operation → Trailer hitch maintenance: checking operation
Airbag system: check operation and condition (see Additional maintenance) → Occupant protection
maintenance: inspecting airbag system
Test drive:
remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering,
transmission, ParkAssist, automatic speed control, PSM switch, heating, air-conditioning system and
instruments: check operation → Test drive - maintenance
Oils, fluids: visual inspection for leaks
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Major maintenance Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Major maintenance
Note
The engine oil and oil filter must be changed every 10,000 km (6,000 mls) in vehicles which are operated in
countries where leaded fuel is used.
If the mileage for scheduled maintenance is not reached, major maintenance must be carried out after 4, 8,
12...... years.
The terms "inspect" and "check" include all necessary subsequent work such as adjustments, readjustments,
corrections and replenishment. They do not include the repair, replacement or overhaul of components or
assemblies.
The maintenance item > Replacing spark plugs < depends on the engine type. Please refer to the "Additional
maintenance" chapter → 287055 Replacing spark plugs [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ 287055
Replacing spark plugs [9PAAD1 9PAAD7].
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Major maintenance Page 3 of 4
Check drive belt → 137801 Checking drive belt [9PAAD1 9PAAD7]→ 137801 Checking drive
belt [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
Steering gear: visual inspection of bellows for damage → Running gear maintenance: steering gear
- fluid level... [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear maintenance: steering
gear - fluid level... [9PAAJ1]
Tie rod joints: check the play and dust bellows → Running gear maintenance: axle joints/drive
shafts [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear maintenance: axle joints/drive
shafts [9PAAJ1]
Power steering: check fluid level → Running gear maintenance: steering gear - fluid
level... [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear maintenance: steering gear -
fluid level... [9PAAJ1]
Fuel lines and connections: visual inspection
Radiators and air inlets: visual inspection for external contamination and blockage; Coolant: check
the level and antifreeze protection → 190101 Checking cooling system
Foot-operated parking brake: check free play → Running gear maintenance: checking free play of
foot-operated parking brake [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear
maintenance: checking free play of foot-operated parking brake [9PAAJ1]
Brake system: visual inspection of brake pads and brake discs for wear → Running gear
maintenance: visual inspection - brake lines/brake pads/brake discs [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ Running gear maintenance: visual inspection - brake lines/brake pads/brake
discs [9PAAJ1]
Brake hoses and lines: visual inspection for damage, routing and corrosion → Running gear
maintenance: visual inspection - brake lines/brake pads/brake discs [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ Running gear maintenance: visual inspection - brake lines/brake pads/brake
discs [9PAAJ1]
Drive shafts: visual inspection of boots for leaks and damage → Running gear maintenance: axle
joints/drive shafts [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear maintenance: axle
joints/drive shafts [9PAAJ1]
Front cardan shaft: visual inspection of air bellows for damage (up to and including '03 model) →
Cardan shaft maintenance [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Cardan shaft
maintenance [9PAAJ1]
Rear cardan shaft: visual inspection of centre bearing for damage (up to and including '03 model) →
Cardan shaft maintenance [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Cardan shaft
maintenance [9PAAJ1]
Axle joints: check the play and visually inspect the dust bellows for damage → Running gear
maintenance: axle joints/drive shafts [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear
maintenance: axle joints/drive shafts [9PAAJ1]
Hydraulically disengagable off-road stabilizer: check fluid level and operation → Hydraulically
disengagable off-road stabilizer- checking fluid level and operation
Exhaust system: visual inspection for leaks and damage, check mounts
Exterior of tyres and spare wheel: check condition and tyre pressure → Running gear maintenance:
tyres and spare wheel - checking condition and tyre pressure [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Running gear maintenance: tyres and spare wheel - checking condition and tyre
pressure [9PAAJ1]
Lubricate door arrester and fastening pins → Checking lid and doors
Panorama roof system: teach control unit → Panorama roof system control unit
Windscreen wiper/washer system, headlight washer: checking operation, fluid level and nozzle
settings, pay attention to antifreeze protection in winter months; check wiper blades → Electrics
maintenance: windscreen wiper and washer system, ...
Seat belts: check operation and condition → Checking seat belts [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ Checking seat belts [9PAAJ1]
All headlights: check adjustment; horn: check operation → Electrics maintenance: checking operation
of vehicle lights
Battery and vent hose: check condition → Battery maintenance: checking condition of battery and
vent hose
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Major maintenance Page 4 of 4
Trailer hitch: check operation → Trailer hitch maintenance: checking operation [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ Trailer hitch maintenance: checking operation [9PAAJ1]
Airbag system: check operation and condition (see Additional maintenance) → Occupant protection
maintenance: inspecting airbag system
Test drive:
remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering,
transmission, ParkAssist, automatic speed control, PSM switch, heating, air-conditioning system and
instruments: check operation → Test drive - maintenance [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Test drive - maintenance [9PAAJ1]
Oils, fluids: visual inspection for leaks
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Diagnosis maintenance: resetting diagnostic system and maintenance interval Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
1. Start Porsche System Tester (PST) and follow the instructions on the Tester.
2. Select vehicle type with >> and perform the automatic control unit search.
3. If a # star appears in front of the relevant control unit, read out the fault memory. Follow the instructions of
the PST.
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Diagnosis maintenance: resetting diagnostic system and maintenance interval Page 3 of 3
Note
If the engine oil is replaced at a service, the maintenance interval must be reset.
1. In the Porsche System Tester, select Instrument cluster, then press >> .
Note
Depending on the country, additional items are checked in the case of the V6 model. These items must be
selected on a country-specific basis.
as of MY 2004
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Passenger protection maintenance: inspecting airbag system Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
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
Visual inspection
1. Check airbag units visually:
1.1. Check that no trim or stickers are attached to the airbag units (driver's, passenger's, side, head airbag).
1.3. The system check must be certified in the stamp spaces provided in the Guarantee and Maintenance
booklet.
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Passenger protection maintenance: inspecting airbag system Page 3 of 5
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.
DANGER
Danger of serious or fatal injuries from passenger's airbag!
If the PASSENGER AIRBAG warning light does not light up when
the ignition is switched on, there may be a fault in the system.
2.1.
2.2. Use the vehicle key to deactivate the passenger's airbag at the key-operated switch (cover of right fuse
carrier).
2.5. Switch on the ignition; the warning light must light up continuously.
WARNING
Performing the drive link test when vehicle is in motion!
Danger of injury if the drive link test is carried out when the vehicle is in motion! The following
conditions must be satisfied when carrying out the drive link test:
→ Never carry out the drive link test when the vehicle is in motion.
→
The drive link test must always be carried out on a stationary vehicle in a workshop with adequate
commercially available tools. The cutoff relay must be activated again following the drive link test. Only then
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Passenger protection maintenance: inspecting airbag system Page 4 of 5
1.7.
1.8. Start the engine and activate central locking system with the switch in the door trim panel.
Note
When you perform the drive link test:
The cutoff relay is activated. The cutoff relay must be activated again. To activate the cutoff relay: Press on
the coloured area of cutoff relay (located in power distributor).
1.10.
1.11. Read out and erase fault memory for the DME control module and airbag control unit.
ATTENTION
Danger of injury and material damage if airbag units are not handled correctly! Always observe the safety
regulations for handling airbag units. → 69 Safety regulations for vehicles with airbag and belt tensioner.
Remove ignition key. Disconnect battery . Route or isolate ground strap so that all contact with a ground
carrier (e.g. body, seat frame) is avoided. → 90 Work instructions after disconnecting the battery . After
the battery is disconnected, always wait one minute before disconnecting the airbag connectors.
1.13.
2.1. Simulate the fault using the side airbag, for example. Move seat all
the way forward.
Note
To check the operation of the airbag system, a plug connection is
disconnected from an airbag unit. A fault code - Static fault - must
then be stored in the Porsche System Tester.
2.2.
2.3. Fold up retainer on plug socket -1- -A- , press lock -B- on airbag connector -2- and pull out connector -C- .
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Passenger protection maintenance: inspecting airbag system Page 5 of 5
3.1. Switch off ignition, disconnect the battery and wait one minute.
3.2. Fold up retainer -A- on plug socket -1- and insert connector -2- -B-
until it is felt to engage.
Note
Fault memory shows a sporadic fault.
4.2.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\033901_0.htm 5/19/2011
Additional spark plug maintenance Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The engine oil and oil filter must be changed every 10,000 km (6,000 mls) in vehicles which are operated in
countries where leaded fuel is used.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\038100_0.htm 5/19/2011
Additional maintenance after 120,000 km/80,000 mls Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The engine oil and oil filter must be changed every 10,000 km (6,000 mls) in vehicles which are operated in
countries where leaded fuel is used.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\038500_0.htm 5/19/2011
Additional maintenance after 240,000 km/160,000 mls Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The engine oil and oil filter must be changed every 10,000 km (6,000 mls) in vehicles which are operated in
countries where leaded fuel is used.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
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Additional maintenance after 240,000 km/160,000 mls Page 3 of 3
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Checking operation of vehicle lights Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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:
Main headlights
Fog lights
Side direction indicator light
Tail light
Number plate light
Additional brake light
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Checking operation of vehicle lights Page 3 of 5
Overview of bulbs
Overview of bulbs
Press horn actuation on steering wheel and check the function and sound of horn.
3. Set the time using the rocker 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.
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Checking operation of vehicle lights Page 4 of 5
Make the adjustment with the regulator switch set to 0 (headlight beam adjustment)!
Use a flexible screwdriver 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 ; tyre pressures must correspond to specified values).
2. Turn on the ignition, turn on dipped beam and high beam headlights.
3. Check setting and adjust if necessary.
Adjusting:
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!
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.
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Checking operation of vehicle lights Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\3087683_KDNum_0.htm 5/19/2011
Checking electrical equipment such as control and warning lights for functionality. Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
– Adjust heater blower and fans to high and low and check the air vents for air throughput.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Entire vehicle -General Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
03 Entire vehicle -General - as of MY 2003
- General warning notes
DANGER
Risk of injury due to vehicles slipping or tilting off lifting platforms.
Risk of injury due to vehicles slipping or tilting off lifting platforms may be caused by improper
alignment of the lifting platform arms or support plates, and by raising, supporting or removing units
on raised vehicles.
ATTENTION
Danger of material damage if the vehicle is raised incorrectly.
Lifting or supporting the vehicle at unsuitable take-up points can lead to material damage on the
vehicle.
Raising the vehicle in the sill area will lead to the deformation of body parts and to leakage in the
underbody area.
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Note
For Cayenne vehicles with air suspension/level control, the following work must also be performed before raising
the vehicle:
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.
Note
If air suspension accumulators of the air suspension are filled, only the ignition has to be switched on. If air
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Entire vehicle -General Page 4 of 4
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.
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.
– 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.
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.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Test drive - maintenance Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The following test items are included in the test drive.
– Activate cruise control during the test drive and check operation.
– Actuate PSM switch during the test drive and check operation.
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Test drive - maintenance Page 3 of 3
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Running gear maintenance: axle joints/drive shafts Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
03 Running gear maintenance: axle joints/drive shafts - as of MY
2004
- Tie rod joints: checking the play and dust bellows
- Axle joints: checking the play and dust bellows
- Drive shafts: visual inspection of the boots
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.
3. Check that dust boots, bellows and joints are functioning correctly and not leaking.
Note
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Running gear maintenance: axle joints/drive shafts Page 3 of 3
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:
Place the vehicle on a lifting platform with the steering lock disengaged.
Perform a visual inspection after cleaning.
Note
Over a small area in the vicinity of the brake cover panels, no visual inspection is possible.
as of MY 2004
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Trailer hitch maintenance: checking operation Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
03 Trailer hitch maintenance: checking operation - as of MY 2004
- Checking operation of the trailer hitch socket
- Checking electrically retractable trailer hitch (AHK)
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. Test cable VAS 1537 A:
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Trailer hitch maintenance: checking operation Page 3 of 6
Test procedure
Note
The LED for permanent positive -9- is lit for the entire duration of the test.
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Trailer hitch maintenance: checking operation Page 4 of 6
Illustration showing the marking on the test equipment, direction indicator light, stop light + with designation 1 - 13
at top and A - D below
1. Switch on the ignition and switch through the following loads in turn:
Switch on left -1- or right direction indicator -4- : the direction indicator and direction indicator pilot light for the
trailer in the instrument cluster light up. Press the relevant key -B- for left or -C- right: during flashing, the LEDs -1-
or -4- and the direction indicator in the instrument cluster should not now light up.
4. Switch on parking light and rear fog light. Switch on parking light - LEDs -5, 7- should light up.
Disconnect the trailer hitch plug. The rear fog light on the vehicle must light up.
General:
-13- Depending on the load (heat build-up) in the test equipment (the more LEDs that are lit up), the tester will
switch off and this is indicated by this LED lighting up. Disconnect the test equipment and let it cool for at least 20
minutes.
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Trailer hitch maintenance: checking operation Page 5 of 6
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.
WARNING
Risk of injury and damage when retracting and extending the hitch ball.
Make sure that no persons, animals or obstacles are in the movement range of the hitch ball.
To interrupt the swivel action of the hitch ball in the event of danger, touch the rocker switch again.
→ 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.
There must not be any accessories on the hitch ball (e.g. ball protection cap, bicycle rack, etc.).
Note
The vehicle must be stationary.
1.2.
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Trailer hitch maintenance: checking operation Page 6 of 6
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.
2.1. Requirements:
Note
The vehicle must be stationary.
There must not be any accessories on the hitch ball (e.g. ball protection cap, bicycle rack, etc.).
2.2.
2.3. To retract:
2.5. >> The hitch ball moves automatically into operating position.
2.6. The red LED in the rocker switch flashes until the operating position is reached.
as of MY 2004
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Running gear maintenance: checking the brake fluid level and changing the brake fluid Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
03 Running gear maintenance: checking the brake fluid level and
changing the brake fluid - as of MY 2004
- Checking brake fluid level
- Changing the brake fluid
Note
The brake fluid level must not exceed the MAX mark.
Observe brake fluid quality. Use only new DOT 4 brake fluid.
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- .
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Running gear maintenance: checking the brake fluid level and changing the brake fluid Page 3 of 3
Note
Observe brake fluid quality. Use only new DOT 4 brake fluid.
The brake fluid change interval is two years using Super 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.
Drain brake fluid from every brake caliper at both bleeder valves.
5. Open every bleeder valve until clear, bubble-free brake fluid emerges
and until the corresponding change quantity per brake caliper is
reached (approx. 250 cm3).
6. Use a transparent hose and a collecting bottle to check the escaping brake fluid accurately for cleanliness,
freedom from air bubbles and to determine the brake fluid used.
7. Tighten the bleeder valves to the specified tightening torque and remove the bleeder hoses → 47 Tightening
torques for brake hydraulic system.
8. Switch off bleeding device and remove the adapter on the brake fluid
reservoir. The brake fluid level in the brake fluid reservoir must be
between the MIN and MAX markings once the vehicle has been filled
and bled. Adjust the brake fluid level if necessary.
as of MY 2004
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Additional maintenance Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Additional maintenance
Note
The engine oil and oil filter must be changed every 10,000 km (6,000 mls) in vehicles which are operated in
countries where leaded fuel is used.
Note
The engine oil and oil filter must be changed every 10,000 km (6,000 mls) in vehicles which are operated in
countries where leaded fuel is used.
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Additional maintenance Page 3 of 3
Note
The engine oil and oil filter must be changed every 10,000 km (6,000 mls) in vehicles which are operated in
countries where leaded fuel is used.
Note
The engine oil and oil filter must be changed every 10,000 km (6,000 mls) in vehicles which are operated in
countries where leaded fuel is used.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Checking wheel mounting Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
03 Checking wheel mounting - as of MY 2004
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.
as of MY 2004
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Cardan shaft maintenance Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
03 Cardan shaft maintenance - as of MY 2004
- Visual inspection of rollers (front cardan shaft)
- Visual inspection of centre bearing (rear cardan shaft)
Note
The air bellows of the cardan shafts may be damaged by external influences e.g. during off-road use or
similar operation.
Consequence: loss of a large amount of grease, ingress of dirt into the universal joint.
2. Inspect air bellows of front cardan shaft for damage. To do this, rotate the cardan shaft in steps through
180°.
3. Install engine guard → 108019 Removing and installing engine guard - chapter on "Installing".
as of MY 2004
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Running gear maintenance: Tyres and spare wheel: checking condition and tyre pressure Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
03 Running gear maintenance: Tyres and spare wheel: checking
condition and tyre pressure - as of MY 2004
- Checking condition
- Cold tyre pressures (at approx. 20° C)
Checking condition
Checking condition
Tyres are a safety element that fulfil the demands placed on them only if they have the correct air pressure and a
sufficient tread depth.
WARNING
Risk of accident if the air pressure in the tyres falls below the minimum, if the tread depth is insufficient
or if there are foreign bodies, pricks, cracks and bulges in the sidewall (ply breakage).
Modified handling behaviour can cause accidents and major material damage.
→ 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 tyres (for cracks, pricks, bulges in the sidewall and/or foreign bodies) must be
carried out.
Note
For vehicles with a tyre pressure monitoring system, which can be
identified by aluminium valves, the tyre pressure should be adjusted
according to the filling information in the multi-function display. To do
this, in the >> Main menu >> Tyre pressure >>
-Settings- << adjust the deviation values so that they are from
0.0 bar to +0.1 bar. Fill the tyres according to the display using the
tyre-inflating device. Example: If the tyre-pressure display shows
>> Settings << - 0.2 bar, then 0.2 bar must be added.
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Running gear maintenance: Tyres and spare wheel: checking condition and tyre pressure Page 3 of 4
Due to the pressure and temperature relationship (0.1 bar/10° C), the
actual pressures displayed in the -Basic tyre pressure screen- in
the multifunction display, or on the pressure gauge of the tyre-
inflating device, may deviate from the required pressure specification
at 20° C on the tyre pressure plate. This is particularly the case if the
tyre air temperature is significantly above (higher values) or
significantly below (lower values) 20° C. Changes in the tyre pressure
are displayed for up to 1 minute in the >> Settings <<.
For vehicles with the tyre pressure monitoring system, always use
plastic valve caps. They protect the valve from dust, dirt, and
moisture and therefore from damage (corrosion, etc.).
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.
Tyre pressures apply to all-season, all-terrain, summer and winter tyres. They also apply only to tyres approved
by Porsche.
Partial load: The tyre 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: tyre sealant)
The spare wheel on the carrier is inflated to 3.4 bar gauge pressure max. During operation, tyres are to be
adjusted to the gauge pressure specified for the particular vehicle axle and load condition.
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Running gear maintenance: Tyres and spare wheel: checking condition and tyre pressure Page 4 of 4
as of MY 2004
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Wheel electronics: reading out battery service life Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
03 Wheel electronics: reading out battery service life - as of MY
2004
The remaining service life of the wheel electronics can be read out with the Porsche System Tester. Before
scheduled maintenance and/or changing a tyre, 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 tyre. The battery for the wheel electronics
cannot be replaced separately.
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Wheel electronics: reading out battery service life Page 3 of 3
as of MY 2004
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Running gear maintenance: visual inspection - brake lines/brake pads/brake discs Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
03 Running gear maintenance: visual inspection - brake
lines/brake pads/brake discs - as of MY 2004
- Brake hoses and lines
- Brake system: visual inspection of the brake pads and brake discs for wear
- Technical data, wear limits
Brake system: visual inspection of the brake pads and brake discs for wear
Brake system: visual inspection of brake pads and brake discs for wear
WARNING
Risk of accident if brake pads and brake discs are not replaced in time.
Injury and material damage due to impaired braking effect.
→ The brake pads must be replaced when the brake pad warning indicator lights up, but no later than when
there is a residual pad thickness of 2 mm.
→ Brake discs must be replaced on reaching the wear limits.
Note
If brake pad wear is indicated by the warning light, the warning contact (sender including line and plug
connection) must also be replaced.
Replacement of the warning contact can be avoided by replacing the brake pads no later than when the pad
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Running gear maintenance: visual inspection - brake lines/brake pads/brake discs Page 3 of 3
However, if only the plastic part of the warning contact is worn, there
is no need to replace it.
3. Carry out visual inspection of the brake discs for wear → 03
TW Maintenance of running gear: visual inspection - brake
lines/brake pads/brake discs - chapter on "Technical values"
as of MY 2004
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Running gear maintenance: steering gear - fluid level and bellows Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Checking
ATTENTION
Increased risk of accident and material damage if too much Pentosin CHF 11 S is filled in or if Pentosin
CHF 11 S comes into contact with the coolant hoses when filling or topping up.
Overfilling of the system with consequent overflow of Pentosin CHF 11 S onto coolant hoses and
other components may occur.
→ Before inspecting the fluid level, run the engine for approx. 20 seconds. Multiple steering operations
(manoeuvring) will alter the fluid level in the reservoir! Check the fluid level.
→ If coolant hoses come into contact with Pentosin, thoroughly clean them with water IMMEDIATELY.
→ Replace visibly swollen coolant hoses.
Damage to the power-assisted steering will occur if there is a shortage of oil in the hydraulic system. Even small
leaks can cause the fluid to escape as a result of the high oil pressure present in the hydraulic circuit and damage
the servo pump.
Grunt-like noises on turning the steering to full lock or foam formation in the reservoir indicate a shortage of oil
and/or the absorption of air. Before filling the reservoir, any existing leaks must be eliminated . In this case the oil
level in the reservoir must be checked with the engine running as well as stopped! If the oil level drops to the
bottom of the reservoir or bubbles rise up, then there is air in the hydraulic system. The system must then be bled
→ 48 Test and assembly work on power steering.
The reservoir is located in the engine compartment, front left under the engine compartment cover -arrow- .
Use only Pentosin CHF 11 S in the reservoir. Pentosin CHF 11 S can be ordered under the following part number:
Quantity supplied 1 litre = 000.043.203.33.
A dipstick with a MIN/MAX marking is mounted on the closure cap of the expansion tank. The marks are for a fluid
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Running gear maintenance: steering gear - fluid level and bellows Page 3 of 3
Note
The MAX mark can be easily
exceeded at higher temperatures!
4. Wipe dipstick. Close and then reopen cap. The fluid level must be in the indicated range (MAX/MIN level at
approx. 20 °C). Top up with Pentosin if necessary.
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.
as of MY 2004
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Checking seat belts Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
03 Checking seat belts - as of MY 2004
- Checking operation
- Checking condition
Checking operation
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.
Checking condition
Condition inspection
If it displays evidence of damage in the form of cuts, fraying, seam tears etc., the seat belt must be replaced.
as of MY 2004
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Running gear maintenance: running gear adjustment/storage of assemblies Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
03 Running gear maintenance: running gear adjustment/storage
of assemblies - as of MY 2004
- Running gear adjustment (wheel alignment values)
- Storage of assemblies and running gear
as of MY 2004
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Running gear maintenance: checking free play of foot-operated parking brake Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
03 Running gear maintenance: checking free play of foot-operated
parking brake - as of MY 2004
- Foot-operated parking brake: checking free play
- Adjusting the foot-operated parking brake
Tools
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.
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!
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Running gear maintenance: checking free play of foot-operated parking brake Page 3 of 4
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 centre console.
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!
The rear wheels must be removed to gain access to the adjustment device → 440519 Removing and installing
wheel - chapter on "removing".
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- !
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!
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).
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Running gear maintenance: checking free play of foot-operated parking brake Page 4 of 4
as of MY 2004
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Windscreen washer/headlight cleaning system: Checking operation, nozzle settings Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
ATTENTION
Danger of material damage if headlights are cleaned incorrectly!
→ 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!
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Windscreen washer/headlight cleaning system: Checking operation, nozzle settings Page 3 of 3
Note
The angle of the spray nozzle can be adjusted by hand.
Sharp objects must not be placed in the nozzle bore as there is a risk of damaging the spray nozzle!
Information
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Battery maintenance: checking condition of battery and battery vent hose Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work - Battery maintenance: Checking condition of battery and battery vent hose
Observe the warning notes and safety regulations for hydrocyanic acid batteries.
1. Move backrest all the way forward. Move front seat all the way up and all the way forward.
2. Release the covers -arrows A- and remove rear seat rail cover caps
-arrows B- .
3. Move front left seat back and up as far as possible. Move backrest
fully forward.
5. Fold the carpet sections forward and unscrew both fastening screws -1- .
6. Fold the seat back as far as possible. With the seat in its folded position, move the seat forward again using
the fore-and-aft adjustment.
7. Open the four tension hooks on the battery case cover using a screwdriver.
8. Remove the battery case cover with ventilation channel.
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Battery maintenance: checking condition of battery and battery vent hose Page 3 of 8
Cut-out relay
Checking condition of battery and battery vent hose
Note
The maintenance-free battery has an inspection glass.
The charge state and acid level of the battery can be checked through
the inspection glass -B- .
If a battery is more than 5 years old and the indicator of the inspection
glass is colourless, replace the battery.
Maintenance-free battery
Colour indication Charge state
Green The battery is charged sufficiently.
Black The battery is not charged or the charge is too low.
Colourless or yellow Critical acid level.
=> Replace battery.
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Battery maintenance: checking condition of battery and battery vent hose Page 4 of 8
WARNING
Improper handling of batteries.
Risk of injury and damage to the environment
→ The accident prevention regulations must be strictly observed when handling battery acids.
→ Wear suitable protective clothing and protective glasses.
→ Only use a torch to illuminate the inside of the battery. Never illuminate the inside of the battery with a naked
flame.
→ Do not handle a naked flame or lighted cigarettes near batteries.
→ Observe the disposal regulations for batteries and sulphuric acid when disposing of batteries.
Note
Use a commercially available battery filling bottle.
The correct acid level of the battery is an important factor for a long service life of the battery.
When the acid level is too low, a capacity loss (performance loss) of the battery occurs, which is caused by
the cell plates drying out. If the cell plates are not surrounded by electrolyte (battery acid), it will lead to
corrosion of the lead plates, the plate bridges and the cell connectors. The result of the corrosion is that
battery functioning cannot be guaranteed. The battery will become useless.
If the acid level is too high, damage can occur by the battery acid (sulphuric acid/water mixture) leaking out of
the battery.
2. Shine a torch into the battery. The electrolyte level of the battery must be at the protruding " lug" .
2.1. If the acid level is too low, refill with distilled water using the battery filling bottle.
3. Screw in battery plugs again and ensure that they are seated correctly.
Note
Make sure the vent hose -A- is not kinked or damaged. If in doubt, replace it.
Vent hose -A- must be inserted in the battery and in the battery box.
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Battery maintenance: checking condition of battery and battery vent hose Page 5 of 8
Central venting
2. Attach the four tension hooks in the battery case cover and close using the screwdriver.
ATTENTION
Risk of material damage to screw connections for seat and seat frame!
→ 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.
4. Screw in fastening screws -1- and put back the carpet sections. →
Tightening torque: 33 ftlb.
5. Clip in front seat trim -C- .
Battery
6. Push rear cover caps onto seat rails -arrows A- and press down the covers -arrows B- until these engage
audibly.
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
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Battery maintenance: checking condition of battery and battery vent hose Page 6 of 8
1.1. Remove twist grip -A- and position it on the bolt -B- .
1.2. Unscrew the bolt and remove it together with the collapsible spare
wheel.
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Battery maintenance: checking condition of battery and battery vent hose Page 7 of 8
5.1. Put on the battery case cover, position it and clip in the four
fastening clips -A- onto the cover.
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.
6. Installing subwoofer:
6.2. Push the electrical plug connections together until the plug is felt to
engage.
6.3. Position electrical plug connection on subwoofer.
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.
7.3. Position both tightening nuts -2- and tighten them. → tightening torque: 1.5 ftlb.
Note
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Battery maintenance: checking condition of battery and battery vent hose Page 8 of 8
8.1.
8.4. Position twist grip -A- and tighten fastening screw -B- hand tight.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing V8 4.5 l engine Page 2 of 35
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Required tools
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The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions are
noted).
Lifting platform
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Tools overview
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Tools overview
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-F- Filling device 9696 See Workshop Equipment Used for vacuum filling of the cooling
Manual 2.2.2 system
-G- Porsche System Tester ll 9588 See Workshop Equipment
Manual 2.2.2
-H- Lifting platform Can be found in Workshop
Equipment Manual, 3.0.13
"WE 1206"
Preliminary work
Preliminary work
If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing air-
conditioning compressor removed during removal of the engine as the replacement engine is delivered with
the new compressor mounted. → 873419 Removing and installing air-conditioning compressor - chapter on
"Removing"
Fix steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering
wheel in centre position with steering wheel holder)! If this is not done, the airbag contact unit will have to be
put in centre position after installation of the steering gear! → 945019 Removing and reinstalling steering-
column switch
Position the vehicle at the take-up points provided on a lifting platform. → Lifting the vehicle [9PAAE1
9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1]
Put on the protective covers.
Produce the OBD II log.
Move the Tiptronic's selector lever to position N.
Remove ignition key.
Disconnect battery . → Work instructions after disconnecting the battery
Remove front wheels. → 440519 Removing and reinstalling wheel - chapter on "Removing"
Remove the front wheel-housing liners. → 505619 Removing and reinstalling front wheel-housing liner -
chapter on "Removing"
Remove engine compartment covers. → 700219 Removing and reinstalling front cover (engine compartment)
- chapter on "Removing"
Allow engine to cool down.
Removing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are described
in the notes.
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V8 engine
1. Remove engine guard with transverse strut. → 108019 Removing and installing engine guard - chapter on
"Removing"
Note
The air quality sensor is located on the cover of the radiator tank. This
must be unclipped.
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4. Loosen the 4 bayonet screws -A- on the plenum panel cover. Then lift
the cover in the middle, release left and right and remove from the
vehicle.
7. Disconnect the connectors from the engine wire harness (white, red,
black and brown). Remove the wiring harness from the retaining clips
and lay it down on the engine.
B+ transfer point
9. Pull the cover of the throttle body up and off.
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Note
In the Cayenne Turbo (M48/50), the boost pressure sensor must also
be disconnected.
11. Release the fastening bolts on the throttle body. To do this, twist both
bolts through 45° in an anti-clockwise direction. The dot on the bolt
must appear as illustrated in the figure.
Boost-pressure sensor
12. Remove the fastening bolts. To do this, take hold of the bolt by the
rubber ring with pliers and pull it out.
13. Pull off the Y-shaped pipe from the throttle body.
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Note
If the engine is to be subsequently transported by crane, the right-hand design cover on cylinder row 5 - 8
should be removed at this point. → 108319 Removing and installing engine cover - chapter on "Removing"
To do this, loosen the 4 fastening screws. Unclip the design cover from
the intake system and slide out at an angle towards the front.
Note
In vehicles with air suspension, the suction line of the compressor must also be removed on the right air
cleaner cover. To do this, unclip the green cap, press circlip -1- inwards and pull off adapter -2- .
16. Remove the air cleaner covers on the right and left. → 242519 Removing and installing air cleaner housing -
chapter on "Removing" [9PAAF1 9PAAJ1]→ 242519 Removing and installing air cleaner housing - chapter
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Filter elements
18. Disconnect the 2 respective oxygen sensor connectors (brown, black)
at the left and right of the water splash panel and unclip the cable from
the supports.
Note
In the Cayenne Turbo (M48/50), the support for the vacuum pump
must also be undone. To do this, unscrew the two fastening screws
and press the pump forward slightly.
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WARNING
Servo oil is aggressive!
Possible danger of injury or damage (swollen hoses, skin
irritation, danger of slipping, etc.)
20. Empty the servo oil reservoir with a syringe. Next, remove the hose
from the reservoir. Close the open connections with plugs.
DANGER
Fuel can escape when fuel line is disconnected.
Risk of fatal injury!
Damage to skin
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24. Disconnect the coolant feed and return lines from the radiator. To do
this, pull out the securing clip and pull off the connection. The clips
should be mounted again immediately so that they are not confused.
Note
The drive belt must be slackened so that the air-conditioning
compressor can be removed later.
25. Slacken the drive belt (a/f 30) and remove from the tensioning roller.
Note
In the Cayenne Turbo (M48/50), the control lines of the ambient air valves on the T-piece should be pulled off.
Note
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Compressed air line on spring strut Control lines of the ambient air valves
The electric plug connection of the height sensor must be
disconnected in vehicles with air suspension or automatic headlight
levelling system.
WARNING
ATF!
Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)
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Ground point of right side member Brake lines in the wheel housing
29. Disconnect the ATF lines on the cooler. To do this, loosen the
fastening screw and pull off the line. Seal open lines with a plug.
Note
In the case of vehicles with Servotronic, an electric plug must also be
removed from the steering gear.
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34. Remove the complete exhaust system from the connection point on the catalytic converter to the tailpipes
→ 260119 Removing and installing exhaust system - chapter on "Removing".
35. Remove rear cardan shaft → 393519 Removing and installing rear cardan shaft [9PAAE1 9PAAE7 9PAAF1]
→ 393519 Removing and installing rear cardan shaft [9PAAJ1].
Note
Do not loosen nut.
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Note
If the transmission is to be separated from the engine after removal, the two lower fastening screws on the
transmission housing and front cardan shaft should be removed at this point, since access to the lifting
platform will be impaired.
WARNING
Servo oil is aggressive!
Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)
Note
On the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be loosened. To do
this, pull out locking spring -1- on the turbocharger adapter. Then loosen hose clamp -2- of the pressure pipe
on the turbocharger.
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Note
Locking clip and line of ambient air Locking spring on turbocharger
It is easier to remove the air-
valve adapter and hose clamp of
conditioning compressor from
turbocharger pressure pipe
its installation position when the engine has already been lowered a
little.
The lines of the air-conditioning compressor remain mounted, so the refrigerant does not need to be
evacuated.
If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing air-
conditioning compressor removed during removal of the engine as the replacement engine is delivered with
the new compressor mounted. → 873419 Removing and installing air-conditioning compressor - chapter on
"Removing"
40. Loosen the 3 fastening screws and disconnect the electric plug from
the air-conditioning compressor. Set the air-conditioning compressor
aside.
Note
For installation, it is a good idea to mark the installation position of the
front axle carrier diagonally at at least two places on the body. To do
this, place the marks vertically with respect to the floor of the body
using a felt-tip pen (e.g. mark along the front-axle carrier mount with
the pen).
Air-conditioning compressor
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Note
Because of the high loosening torque, the 6 fastening screws on the front-axle carrier can now be loosened.
Loosen the screws by a maximum of one turn.
43. Place the elevating platform under the engine and raise it. When you
do this, ensure that the positioning guides of the elevating platform are
inserted into the body.
Elevating platform
44. Secure the spring struts. To do this, turn the rubber discs upwards
until they are set under the steering knuckle. Then tighten the
retaining brackets on the wheel hub and elevating platform.
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46. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine transverse
bar with locking screws.
47. Loosen the 4 fastening screws on the front-axle carrier and the 2
fastening screws on the engine transverse bar.
Note
When lowering the engine, make sure that cables or lines do not get
mounted accidentally between engine and body. Thus a second person
should make sure that the cables and lines do not get caught.
48. Lower the lifting platform slowly. When this is done, a second person
should ensure that there is sufficient clearance around the engine
compartment and wheel housings.
Fastening screws for front-axle carrier
and fastening screws for engine
transverse bar
Installing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are described
in the notes.
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Overview of V8 engine
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.
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section on "Removing" [9PAAE1 9PAAE7]→ 267619 Removing and installing primary catalytic converter -
section on "Removing" [9PAAF1 9PAAJ1]
6. Bolt the main catalytic converter supports onto the transmission cross
member. For details see → 267319 Removing and installing (main)
catalytic converter - section on "Installing"
7. Remove the support from under the oil pan and remove the tipping
protection from the engine cross member.
9. Pre-fit the drive belt. Mount the drive belt on the pulleys as far as
possible.
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 Oxygen sensor cable for the rear
the transmission. oxygen sensors
When moving the unit into the body, put the air-conditioning compressor into installation position.
Note
Position the front-axle carrier back in the original, marked installation
position and be careful not to damage adjacent parts.
Air-conditioning compressor
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, see → 400619 Removing and installing
front axle carrier - section on "Installing" [9PAAJ1]→ 400619 Removing and installing front axle carrier -
section on "Installing" [9PAAE1 9PAAE7 9PAAF1] → Initial tightening: 120 (89 ftlb.) Nm → Final
tightening - torque angle: 180 °
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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.
Note
For vehicles with Servotronic, the electric connector on the steering
gear must also be connected.
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ATF lines
→ 386219 23 Removing and installing the line for ATF cooling - section on "Installing" [9PAAE7].
25. Mount the ground point of the generator on the right side member. →
Tightening torque: 20 (15 ftlb.) Nm
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Note
In the case of vehicles with air suspension, the compressed air lines
must also be screwed on.
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Brake lines in the wheel housings Sensor for headlight levelling system
33. Fit the electric connections of the spring struts. To do this, connect
cable -1- and then fasten supports -2 and 3- .
34. Lower the vehicle.
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
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Plug connections for oxygen sensors Line from carbon canister and fuel line
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.
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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
45. Position and tighten drive belt on all pulleys → 137819 Removing and installing drive belt - section on
"Installing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing drive belt - section on "Installing" [9PAAE1
9PAAE7].
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
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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.
Air-cleaner element
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.
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Note
In the Cayenne Turbo
(M48/50), the control lines of
the ambient air valve on the T-
piece must also be connected.
Control lines of the ambient air valves Air cleaner with cover
on T-piece
Note
Clip on the leads when mounting the Y-shaped pipe on the bottom.
Clipping in lines
50. Attach the vacuum line to the underside of the Y-shaped pipe.
Vacuum line
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.
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Boost-pressure sensor
52. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the left
and right fastening bolts. Turn both bolts 45° clockwise.
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Subsequent work
Subsequent work
1. Fill and bleed the cooling system. → 193817 Draining and filling in coolant (includes bleeding) - chapter on
"Filling in"
4. Mount the wiper arms. → 922519 Removing and reinstalling wiper arm - chapter on "Installing".
5. Mount engine compartment covers. → 700219 Removing and reinstalling front cover (engine compartment) -
chapter on "Installing"
8. Bleed offroad stabiliser if necessary. → 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter on
"Adjusting and bleeding" [9PAAJ1]→ 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter on
"Adjusting and bleeding" [9PAAE1 9PAAE7 9PAAF1]
9. Mount front wheels. → 440519 Removing and reinstalling wheel - chapter on "Installing"
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. → 873419 Removing and reinstalling air-
conditioning compressor - chapter on "Installing" and → 870317 Evacuating and filling in refrigerant - chapter
on "filling"
12. Fit engine guard. → 108019 Removing and installing engine guard -
chapter on "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.
Engine guard
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Required tools
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The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions are
noted).
Lifting platform
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Tools overview
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Tools overview
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-F- Filling device 9696 See Workshop Equipment Used for vacuum filling of the cooling
Manual 2.2.2 system
-G- Porsche System Tester ll 9588 See Workshop Equipment
Manual 2.2.2
-H- Lifting platform Can be found in Workshop
Equipment Manual, 3.0.13
"WE 1206"
Preliminary work
Preliminary work
If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing air-
conditioning compressor removed during removal of the engine as the replacement engine is delivered with
the new compressor mounted. → 873419 Removing and installing air-conditioning compressor - chapter on
"Removing"
Fix steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering
wheel in centre position with steering wheel holder)! If this is not done, the airbag contact unit will have to be
put in centre position after installation of the steering gear! → 945019 Removing and reinstalling steering-
column switch
Position the vehicle at the take-up points provided on a lifting platform. → Lifting the vehicle [9PAAE1
9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1]
Put on the protective covers.
Produce the OBD II log.
Move the Tiptronic's selector lever to position N.
Remove ignition key.
Disconnect battery . → Work instructions after disconnecting the battery
Remove front wheels. → 440519 Removing and reinstalling wheel - chapter on "Removing"
Remove the front wheel-housing liners. → 505619 Removing and reinstalling front wheel-housing liner -
chapter on "Removing"
Remove engine compartment covers. → 700219 Removing and reinstalling front cover (engine compartment)
- chapter on "Removing"
Allow engine to cool down.
Removing engine
Removing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are described
in the notes.
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V8 engine
1. Remove engine guard with transverse strut. → 108019 Removing and installing engine guard - chapter on
"Removing"
Note
The air quality sensor is located on the cover of the radiator tank. This
must be unclipped.
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4. Loosen the 4 bayonet screws -A- on the plenum panel cover. Then lift
the cover in the middle, release left and right and remove from the
vehicle.
7. Disconnect the connectors from the engine wire harness (white, red,
black and brown). Remove the wiring harness from the retaining clips
and lay it down on the engine.
B+ transfer point
9. Pull the cover of the throttle body up and off.
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Note
In the Cayenne Turbo (M48/50), the boost pressure sensor must also
be disconnected.
11. Release the fastening bolts on the throttle body. To do this, twist both
bolts through 45° in an anti-clockwise direction. The dot on the bolt
must appear as illustrated in the figure.
Boost-pressure sensor
12. Remove the fastening bolts. To do this, take hold of the bolt by the
rubber ring with pliers and pull it out.
13. Pull off the Y-shaped pipe from the throttle body.
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Note
If the engine is to be subsequently transported by crane, the right-hand design cover on cylinder row 5 - 8
should be removed at this point. → 108319 Removing and installing engine cover - chapter on "Removing"
To do this, loosen the 4 fastening screws. Unclip the design cover from
the intake system and slide out at an angle towards the front.
Note
In vehicles with air suspension, the suction line of the compressor must also be removed on the right air
cleaner cover. To do this, unclip the green cap, press circlip -1- inwards and pull off adapter -2- .
16. Remove the air cleaner covers on the right and left. → 242519 Removing and installing air cleaner housing -
chapter on "Removing" [9PAAF1 9PAAJ1]→ 242519 Removing and installing air cleaner housing - chapter
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Filter elements
18. Disconnect the 2 respective oxygen sensor connectors (brown, black)
at the left and right of the water splash panel and unclip the cable from
the supports.
Note
In the Cayenne Turbo (M48/50), the support for the vacuum pump
must also be undone. To do this, unscrew the two fastening screws
and press the pump forward slightly.
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WARNING
Servo oil is aggressive!
Possible danger of injury or damage (swollen hoses, skin
irritation, danger of slipping, etc.)
20. Empty the servo oil reservoir with a syringe. Next, remove the hose
from the reservoir. Close the open connections with plugs.
DANGER
Fuel can escape when fuel line is disconnected.
Risk of fatal injury!
Damage to skin
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24. Disconnect the coolant feed and return lines from the radiator. To do
this, pull out the securing clip and pull off the connection. The clips
should be mounted again immediately so that they are not confused.
Note
The drive belt must be slackened so that the air-conditioning
compressor can be removed later.
25. Slacken the drive belt (a/f 30) and remove from the tensioning roller.
Note
In the Cayenne Turbo (M48/50), the control lines of the ambient air valves on the T-piece should be pulled off.
Note
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Compressed air line on spring strut Control lines of the ambient air valves
The electric plug connection of the height sensor must be
disconnected in vehicles with air suspension or automatic headlight
levelling system.
WARNING
ATF!
Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)
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Ground point of right side member Brake lines in the wheel housing
29. Disconnect the ATF lines on the cooler. To do this, loosen the
fastening screw and pull off the line. Seal open lines with a plug.
Note
In the case of vehicles with Servotronic, an electric plug must also be
removed from the steering gear.
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34. Remove the complete exhaust system from the connection point on the catalytic converter to the tailpipes
→ 260119 Removing and installing exhaust system - chapter on "Removing".
35. Remove rear cardan shaft → 393519 Removing and installing rear cardan shaft [9PAAE1 9PAAE7 9PAAF1]
→ 393519 Removing and installing rear cardan shaft [9PAAJ1].
Note
Do not loosen nut.
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Note
If the transmission is to be separated from the engine after removal, the two lower fastening screws on the
transmission housing and front cardan shaft should be removed at this point, since access to the lifting
platform will be impaired.
WARNING
Servo oil is aggressive!
Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)
Note
On the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be loosened. To do
this, pull out locking spring -1- on the turbocharger adapter. Then loosen hose clamp -2- of the pressure pipe
on the turbocharger.
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Note
Locking clip and line of ambient air Locking spring on turbocharger
It is easier to remove the air-
valve adapter and hose clamp of
conditioning compressor from
turbocharger pressure pipe
its installation position when the engine has already been lowered a
little.
The lines of the air-conditioning compressor remain mounted, so the refrigerant does not need to be
evacuated.
If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing air-
conditioning compressor removed during removal of the engine as the replacement engine is delivered with
the new compressor mounted. → 873419 Removing and installing air-conditioning compressor - chapter on
"Removing"
40. Loosen the 3 fastening screws and disconnect the electric plug from
the air-conditioning compressor. Set the air-conditioning compressor
aside.
Note
For installation, it is a good idea to mark the installation position of the
front axle carrier diagonally at at least two places on the body. To do
this, place the marks vertically with respect to the floor of the body
using a felt-tip pen (e.g. mark along the front-axle carrier mount with
the pen).
Air-conditioning compressor
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Note
Because of the high loosening torque, the 6 fastening screws on the front-axle carrier can now be loosened.
Loosen the screws by a maximum of one turn.
43. Place the elevating platform under the engine and raise it. When you
do this, ensure that the positioning guides of the elevating platform are
inserted into the body.
Elevating platform
44. Secure the spring struts. To do this, turn the rubber discs upwards
until they are set under the steering knuckle. Then tighten the
retaining brackets on the wheel hub and elevating platform.
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46. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine transverse
bar with locking screws.
47. Loosen the 4 fastening screws on the front-axle carrier and the 2
fastening screws on the engine transverse bar.
Note
When lowering the engine, make sure that cables or lines do not get
mounted accidentally between engine and body. Thus a second person
should make sure that the cables and lines do not get caught.
48. Lower the lifting platform slowly. When this is done, a second person
should ensure that there is sufficient clearance around the engine
compartment and wheel housings.
Fastening screws for front-axle carrier
and fastening screws for engine
transverse bar
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Required tools
The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions are
noted).
Lifting platform
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Tools overview
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Tools overview
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-F- Filling device 9696 See Workshop Equipment Used for vacuum filling of the cooling
Manual 2.2.2 system
-G- Porsche System Tester ll 9588 See Workshop Equipment
Manual 2.2.2
-H- Lifting platform Can be found in Workshop
Equipment Manual, 3.0.13
"WE 1206"
Installing engine
Installing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are described
in the notes.
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Overview of V8 engine
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.
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7. Remove the support from under the oil pan and remove the tipping
protection from the engine cross member.
9. Pre-fit the drive belt. Mount the drive belt on the pulleys as far as
possible.
Note
When moving the unit into the body, ensure that the shift cable is on
the transmission. Oxygen sensor cable for the rear
oxygen sensors
When moving the unit into the body, put the air-conditioning compressor into installation position.
Note
Position the front-axle carrier back in the original, marked installation
position and be careful not to damage adjacent parts.
Air-conditioning compressor
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, see → 400619 Removing and
installing front axle carrier - section on "Installing" [9PAAJ1]→ 400619 Removing and installing front axle
carrier - section on "Installing" [9PAAE1 9PAAE7 9PAAF1] → Initial tightening: 120 (89 ftlb.) Nm → Final
tightening - torque angle: 180 °
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Connector to transmission
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18. Mount selector lever cable. For details see → 371519 Removing and installing selector lever cable - section
on "Installing" [9PAAE1 9PAAF1 9PAAJ1]→ 371519 23 Removing and installing selector lever cable -
section on "Installing" [9PAAE7].
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.
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 see → 489019 Removing and installing steering
gear - section on "Installing".
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22. Slide the heater coolant lines on the left side member and mount the
clips.
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ATF lines
25. Mount the ground point of the generator on the right side member. →
Tightening torque: 20 (15 ftlb.) Nm
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30. Screw the front apron onto the transverse strut. → Tightening
torque: 5 (3.5 ftlb.) Nm
Note
In the case of vehicles with air suspension, the compressed air lines
must also be screwed on.
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33. Fit the electric connections of the spring struts. To do this, connect
cable -1- and then fasten supports -2 and 3- .
37. Connect the servo line to the reservoir and mount the spring band clamp. Then fill the container with
Pentosin.
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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
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
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Fastening screws for vacuum pump Plug connections for oxygen sensors
support
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
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- .
45. Position and tighten drive belt on all pulleys → 137819 Removing and installing drive belt - section on
"Installing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing drive belt - section on "Installing" [9PAAE1
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Bayonet screws for plenum chamber Fastening screws for the central
cover electrical system box
Drive belt
9PAAE7].
46. Connect the upper left coolant connection piece to the radiator. The
connection piece must engage audibly.
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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.
Air-cleaner element
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.
Clipping in lines
50. Attach the vacuum line to the underside of the Y-shaped pipe.
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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.
Boost-pressure sensor
52. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the left
and right fastening bolts. Turn both bolts 45° clockwise.
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Subsequent work
Subsequent work
1. Fill and bleed the cooling system. → 193817 Draining and filling in coolant (includes bleeding) - chapter on
"Filling in"
4. Mount the wiper arms. → 922519 Removing and reinstalling wiper arm - chapter on "Installing".
5. Mount engine compartment covers. → 700219 Removing and reinstalling front cover (engine compartment) -
chapter on "Installing"
8. Bleed offroad stabiliser if necessary. → 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter on
"Adjusting and bleeding" [9PAAJ1]→ 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter on
"Adjusting and bleeding" [9PAAE1 9PAAE7 9PAAF1]
9. Mount front wheels. → 440519 Removing and reinstalling wheel - chapter on "Installing"
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. → 873419 Removing and reinstalling
air-conditioning compressor - chapter on "Installing" and → 870317 Evacuating and filling in refrigerant -
chapter on "filling"
12. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "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.
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Engine guard
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
DANGER
Hot water under high pressure!
Risk of damage for engine components.
Incoming washer-fluid in electric components.
Note
The engine should be washed only if this is absolutely essential for repair work.
Cleaning agents or water should never be applied directly to components that are sensitive to moisture, such
as electric connectors.
When using high-pressure cleaning apparatus, maintain a minimum clearance of 50 cm between the
cleaning lance and the engine component.
For environmental reasons, the engine may only be washed in workshops in which oils are separated from
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waste water.
2. Protect components sensitive to moisture, possibly by covering them with plastic sheeting. Oxygen sensor
connectors must not get wet.
3. Remove any maintenance labels (e.g. oil change schedule tag) and replace after the work is completed.
5. Spray engine components to be cleaned with an appropriate engine cleaning agent and allow it to work in.
6. Clean the engine. Ensure that a minimum clearance of 50 cm is maintained between the cleaning lance and
engine component. The water temperature must not exceed 80 °C. Remove persistent dirt with a non-
abrasive sponge.
7. Moving components in the engine compartment, such as the hook for the bonnet, must be re-greased.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Note
The special tools that are required are described in the chapter → (Special) tools required for repairing the
M48/00 and M48/50 engines or in the corresponding individual chapters.
Technical values
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Technical values
Note
For information on all tightening torques, see → Tightening torques for Cayenne S (M48/00) and Cayenne
Turbo (M48/50) [9PAAF1 9PAAJ1]→ Tightening torques for Cayenne S (M48/00) and Cayenne Turbo
(M48/50) [9PAAE1 9PAAE7] or the corresponding individual chapters.
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove engine from transmission. → 343527 Removing and refitting the transmission [9PAAE7]→ 343527
Removing and refitting the transmission [9PAAE1 9PAAF1 9PAAJ1] or → 373527 Removing and refitting
the transmission [9PAAE1 9PAAF1 9PAAJ1]→ 373527 Removing and refitting the transmission [9PAAE7]
Note
The engine must be disassembled in accordance with the detailed
descriptions in the Technical Manual!
4. Remove wire harness for engine. → 975219 Removing and installing wire harness for engine - section on
"Removing" [9PAAE1 9PAAE7]→ 975219 Removing and installing wire harness for engine - section on
"Removing" [9PAAF1 9PAAJ1]
5. Remove the generator. → 272219 Removing and installing generator - section on "Removing" [9PAAE1
9PAAE7]→ 272219 Removing and installing generator - section on "Removing" [9PAAF1 9PAAJ1]
6. Remove power-steering pump. → 489819 Removing and installing hydraulic pump (Cayenne
Turbo/Cayenne S) - section on "Removing"
7. Remove left additional assembly bracket -2- and right engine carrier -8- . There are also two dowel sleeves
(not shown) on the additional assembly bracket.
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1- Nut → Tightening torque: 75 (56 ftlb.) Nm
2- Additional assembly bracket, left
3- Screw x 10 → Tightening torque: 65 (48 ftlb.) Nm
4- Hydraulic mount, left
5- Engine carrier
6- Screw x 4 → Tightening torque: 60 (44 ftlb.) Nm
7- Hydraulic mount, right
8- Engine carrier
9- Screw x 6 → Tightening torque: 65 (48 ftlb.) Nm
Disassembling engine
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Disassembling engine
1. Remove starter. → 276019 Removing and installing starter - section on "Removing" [9PAAE1 9PAAE7
9PAAF1]→ 276019 21 Removing and installing starter - section on "Removing" [9PAAJ1]
2. Remove knock sensors. → 287219 Removing and installing knock sensor - section on "Removing"
4. Remove water pump. → 195019 Removing and installing coolant pump - section on "Removing"
5. Remove coolant regulator. → 195819 Removing and installing coolant regulator (thermostat) - section on
"Removing"
8. Remove oil spray jets on turbo engine and cap on naturally aspirated engine. → 101321 Removing oil spray
jets for piston cooling [9PAAF1 9PAAJ1]→ 101321 Removing oil spray jets for piston cooling [9PAAE1
9PAAE7]
Preliminary work
Note
The engine must be disassembled in accordance with the detailed
descriptions in the Technical Manual!
Assembling engine
Assembling engine
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
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sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
Note
The engine must be disassembled in accordance with the detailed
descriptions in the Technical Manual!
Note
Four oil spray nozzle are installed in the M48/50 engine instead of the Caps and oil spray nozzles
caps used in the M48/00 engine.
1. Fit caps on crankcase. When doing so, make sure that new O-rings are fitted. Tighten the → Tightening
torque: 10 (7.5 ftlb.) Nm .
Note
The bearing shells are available in various tolerance classes. The
classes are indicated by the colour marking on the outside. The
colour marking must match the corresponding colour dot on the
crankshaft. Further details: → Removing and installing crankshaft
2. Insert the bearing shells with the lubricating groove into the upper
part of the crankcase → Inserting the bearing shells . Make sure the
twist locks are positioned correctly. Then lightly oil the bearing
locations.
Colour marking on bearing shell
3. Insert the sickle-shaped washer (make sure of axial bearing play). To do this, insert the two sickle-shaped
washers to the left and right on crankshaft bearing no. 3. Apply some grease (000.043.204.17) between the
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WARNING
The crankshaft is heavy!
There is a danger of hands being crushed when inserting the
crankshaft.
4. Insert crankshaft. The connection flange must point towards the back
of the engine. Then secure the crankshaft from falling down using Crankshaft holding bridges
holding bridges 9677. Attach the holding bridges at bearing
locations 3 and 5 → Crankshaft holding bridges . Then screw the
fastening screw of the front pulley into the crankshaft until they just
make contact.
Note
The pistons must already be pre-fitted (pistons, piston rings,
connecting rods and fastening material) before performing the next
step.
When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel.
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6. Install piston. To do this, turn the crankshaft with a wrench (a/f 27)
until the corresponding lift pin is pointing straight downwards.
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10. Push the piston downwards until the connecting-rod bearing is sitting on the lift pin. Then fit connecting-rod
bearing cap with bearing shell. The connecting rod numbers must face each other. Screw in con-rod bolts by
hand. Make sure the twist locks and connecting rod code are positioned correctly during assembly.
Note
Con-rod bolts must always be replaced.
14. Tighten con-rod bolts that have been replaced. See → 131019 View of connecting rod numbers
Removing and installing pistons - section on "Installing"
16. Screw the two thin centring pins 9321 into the outer fastening bores
on the upper part of the crankcase -Arrows- (crankshaft not fitted in
illustration).
Centring pin
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17. Insert the bottom bearing shells into the bottom section of the crankcase (bed plate) and lightly oil running
surfaces. Pay attention to the twist locks when doing so.
18. Make sure the crankcase is ready to be screwed in. Check that the sickle discs are positioned correctly.
Degrease parting surfaces between top and bottom section of crankcase. A totally grease-free product (e.g.
brake cleaner) must be used for this. Then insert a new O-ring at the front of the parting surface.
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Note
Liquid sealant must be applied and screws tightened immediately and without interruption.
The threads and head contact surface of the bearing seat screws (M10 x 1.5 and M12 x 1.5) must be oiled.
19. Apply Loctite 5970 liquid sealant - 000.043.300.39 (status 11/2005, for details of current sealant, see Parts
Catalogue) to the lower part of the crankcase as shown. The surfaces marked -A- must be cleaned after
fitting.
20. Place bottom section of crankcase into position. When doing so, make sure that the sealing bead is not
destroyed.
21. For details of the tightening sequence for the bottom section of the crankcase and tightening torques, see
→ 134819 Removing and installing crankshaft - section on "Installing".
22. Then tighten the four fastening screws on the clutch side →
Tightening torque: 23 (17 ftlb.) Nm -Arrows- .
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24. Install oil pump. → 172019 Removing and installing oil pump -
section on "Installing"
25. Fit guide rail -9- and tensioning rail -6- for the oil pump drive. Push
the tensioning rail over the fastening pin and engage the guide rail in
the bottom section of the crankcase as shown in the illustration.
Oil pump
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26. Fit timing chain cover on oil pump. Tighten the → Tightening
torque: 10 (7.5 ftlb.) Nm .
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31. Mount cylinder heads. To do this, turn the engine on the assembly
support so that the required cylinder bank is pointing vertically
upwards.
Cylinder bank 1 - 4
33. Fit cylinder head. The fastening screws must be tightened in the
sequence shown below. The tightening sequences and step-by-step
tightening torques must be observed! For details, see → 157023
Removing and installing cylinder head.
Cylinder bank 5 - 8
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34. Fit camshaft housing. Apply a bead of Loctite 5970 liquid sealant - 000.043.300.39 (status 11/2005, for
details of current sealant, see Parts Catalogue) -A- as shown. Then screw two thin centring pins 9321 into
two opposing blind holes in the cylinder head. Insert the O-ring -B- into the oil duct. Wipe off any sealant -C-
that emerges as a result of screwing.
Sealant application
35. Position camshaft housing and then unscrew the two centring pins.
36. Tighten the camshaft housing screws in the sequence shown. Don't forget the two hexagon socket head
bolts at the front of the camshaft housing. For details, see → 150323 Removing and installing camshaft
housing.
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Note
The bearing locations of the camshafts must be lightly oiled.
Place the camshafts in such a way that the cams are positioned as
shown below!
Positioning camshafts
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38. Fit oil return line to camshaft housing 5 - 8. Fit oil return line -1- with a new O-ring -2- . Tighten the four →
Tightening torque: 10 (7.5 ftlb.) Nm -3 and 4- (camshaft housing, cylinder head, crankcase and oil pan).
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39. Position oil feed housing of inlet camshaft and tighten → Tightening torque: 10 (7.5 ftlb.) Nm .
Note
If the camshaft timing gears and camshaft adjusters are removed completely, the diamond washers and
fastening screws must be replaced!
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Diamond washer
40. Replace the diamond washer and fastening screw located underneath the camshaft adjuster and camshaft
timing gear.
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Deflection rail
ATTENTION
Damage to the camshaft switch-over valve!
Malfunction.
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45. Install timing chain. Position the chain on the crankshaft gear wheel
and then fit it over all four camshaft timing gears. To do this, use both
hands to carefully insert the camshaft adjuster and camshaft timing
gear into the timing chain. Screw in fastening screws of the timing
gears loosely to half a turn. Figure → Installing timing chain shows
procedure with timing-case cover fitted. Screw in fastening screws of
the timing gears loosely to half a turn.→ 153523 Installing timing
chain
46. Fit U-rail. Insert the U-rail into the timing drive mechanism from
above. Tighten the four fastening screws.
Guide rails
49. Place sealing ring over crankshaft using assembly sleeve.
51. Tighten the two upper fastening screws (M6 x 50) and the lower fastening screws (M6 x 12) by hand. Then
tighten the screws crosswise. → Tightening torque: 10 (7.5 ftlb.) Nm
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Assembly sleeve
Note
If the sealing flange on the pulley is slightly rusted, polish the rust off
with a special polishing pad (e.g. Never Dull).
Note
A feather key is inserted into the crankshaft. When fitting the pulley, Crankshaft belt pulley
ensure that the feather key slots into the groove in the pulley.
53. Fit crankshaft belt pulley.→ 137619 Removing and installing crankshaft belt pulley - section on "Installing"
54. Fit oil pan. → 175023 Oil pan installed (includes sealing)
Note
To remove the play from the timing chain for the setting process, the crankshaft must be positioned approx.
45° in front of the TDC of cylinder 1 before turning!
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Subsequent work
Subsequent work
1. Fit left additional assembly bracket -2- and right engine carrier -8- . There are still two dowel sleeves (not
shown) on the additional assembly bracket.
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1- Nut → Tightening torque: 75 (56 ftlb.) Nm
2- Additional assembly bracket, left
3- Screw x 10 → Tightening torque: 65 (48 ftlb.) Nm
4- Hydraulic mount, left
5- Engine carrier
6- Screw x 4 → Tightening torque: 60 (44 ftlb.) Nm
7- Hydraulic mount, right
8- Engine carrier
9- Screw x 6 → Tightening torque: 65 (48 ftlb.) Nm
2. Fit power-steering pump. → 489819 Removing and installing hydraulic pump (Cayenne Turbo/Cayenne S) -
section on "Installing"
3. Fit generator. → 272219 Removing and installing generator - section on "Installing" [9PAAE1 9PAAE7]
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4. Fit wire harness for engine. → 975219 Removing and installing wire harness for engine - section on
"Installing" [9PAAE1 9PAAE7]→ 975219 Removing and installing wire harness for engine - section on
"Installing" [9PAAF1 9PAAJ1]
5. Refit engine on transmission. → 343527 Removing and refitting the transmission [9PAAE7]→ 343527
Removing and refitting the transmission [9PAAE1 9PAAF1 9PAAJ1] or → 373527 Removing and refitting
the transmission [9PAAE1 9PAAF1 9PAAJ1]→ 373527 Removing and refitting the transmission [9PAAE7]
6. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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The most important working regulations and warning notes Page 2 of 12
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Folder 1
Group 1 - Engine
DANGER
Suspended load!
Risk of serious crushing and injury
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
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DANGER
Danger of injury from incorrect use of tools and from falling loads!
Danger of crushing from heavy loads!
→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ Never use defective lifting equipment (bent or damaged tools must not be used or repaired. Always replace
these tools). Check tools for signs of damage before use.
→ Only use lifting equipment tested and approved by Porsche. Home-made and auxiliary constructions result
in improper use and are dangerous.
→ The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e.g. from
chains or cables) will damage the transport eyebolt, which must then be replaced. Extreme cases of
improper use can break the transport eyebolt.
→ Tools and lifting equipment must always be used properly. Improper use or dangerous home-made
constructions can break tools and result in falling loads.
→ Wear protective gloves.
DANGER
Danger of poisoning from silicone, grease and oil!
Danger of poisoning and damage to skin
Note
When working on the crank mechanism, absolute cleanliness is essential.
Only the auxiliary and assembly equipment recommended for the repair job may be used for the particular
assembly work.
Only the auxiliary materials recommended by Porsche (such as lubricants or sealants) may be used.
All screw fittings must be tightened according to the prescribed torque or torque angle.
DANGER
Danger of poisoning from silicone, grease and oil!
Danger of poisoning and damage to skin
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DANGER
Danger of injury from rotating components and belt drive!
Risk of severe hand injuries.
WARNING
Do not remove the drive belt when the engine is warm!
Risk of damage or deformation!
→ Drive belts should only be removed when they have cooled down.
DANGER
Danger of injury from running radiator fans (electric fans)!
Risk of severe hand injuries.
→ The vehicle fans can continue running or start up when the ignition is switched off.
→ The power supply to the fans must be disconnected before starting work on the radiator or radiator fans.
(Remove fuse → Fuse carrier [9PAAE1 9PAAE7 9PAAF1]→ Fuse carrier [9PAAD1 9PAAD7 9PAAJ1]).
Note
Work on the crank mechanism/pistons must be carried out very carefully and in clean conditions.
During work interruptions, the open engine or components must be covered to protect them from dirt.
Only processing materials (silicones, oils, greases, etc.) approved by Porsche may be used.
All screw fittings must be tightened according to the prescribed torque or torque angle.
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Note
Only processing materials (silicones, oils, greases, etc.) approved by Porsche may be used.
All screw fittings must be tightened according to the prescribed torque or torque angle.
DANGER
Danger of poisoning from silicone, grease and oil!
Danger of poisoning and damage to skin
Note
Work on the valve drive must be carried out very carefully and in clean conditions.
During work interruptions, the open engine or components must be covered to protect them from dirt.
Only the auxiliary materials recommended by Porsche (such as lubricants or sealants) may be used.
All screw fittings must be tightened according to the prescribed torque or torque angle.
Group 17 - Lubrication
WARNING
Engine oil is toxic.
Danger of poisoning!
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WARNING
Danger of scalding from hot oil!
→ Engine oil and components of the oil circuit can become very hot!
→ Allow engine and components to cool down.
→ Avoid contact with the skin and eyes.
→ Wear suitable protective clothing.
WARNING
Oil is combustible!
Risk of fire due to oil and hot components (exhaust manifold, etc.)
→ Do not pour engine oil over very hot components (e.g. turbocharger).
→ Never place cloths soaked with oil on hot engine components.
→ In case of fire, use CO2 or dry powder fire extinguishers.
Note
Only oils with the appropriate viscosity and approved by Porsche may be used.
During an oil change, the old oil must be drained from the engine via the drain plugs provided. Extraction by
suction is not recommended.
Engine oil and oil filters must be disposed of according to the respective, applicable national laws.
Seals in the oil circuit must be replaced by new ones following disassembly.
Group 19 - Cooling
ATTENTION
Danger of poisoning!
Coolant additives and cleaning liquids are toxic.
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ATTENTION
Danger of scalding with hot coolant!
→ Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause scalding.
→ The cooling system must be depressurised before being opened.
→ Allow engine to cool down.
DANGER
The vehicle fans can continue running or start up automatically.
Injuries which can lead to the loss of body parts.
→ The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or the
belt drive. → Disconnect fuse carrier [9PAAE1 9PAAE7 9PAAF1]→ Disconnect fuse carrier [9PAAD1
9PAAD7 9PAAJ1] or battery → Work instructions after disconnecting the battery
ATTENTION
Risk of damaging the cooling system!
→ Do not relieve the system pressure of the cooling system and then run the engine.
→ Relieving the system pressure and subsequently starting the engine can cause severe damage to
components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling
system to cool down before starting the engine again.
Note
The coolant filled in at the factory is intended to suffice for the entire service life. As long as the coolant is not
contaminated by foreign bodies or other fluids it need not be changed.
Different coolant additives must not be mixed and doing so may damage the cooling system. Only use
original Porsche coolant additives.
The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50 : 50
(coolant additive : water). This mixing ratio provides optimum corrosion and antifreeze protection.
Coolant additives, coolants and cleaning agents must be disposed of according to the respective, applicable
national laws.
Seals in the cooling system must be replaced by new ones following disassembly.
Information
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DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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ATTENTION
Danger of burns from very hot components (turbocharger, exhaust manifold)!
Note
After the connecting clamps in the exhaust system have been released, they must always be replaced.
During assembly work on the exhaust system, ensure that the components are aligned and installed
correctly.
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
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Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
ATTENTION
The oxygen sensor may be damaged if handled incorrectly.
Change in engine emissions.
Damage to the environment.
Check Engine lamp may come on.
→ Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread grease
must never come into contact with the connector.
→ Protect sensors - before and after fitting - against mechanical shocks.
→ Sensors that were dropped on the floor must not be used owing to the risk of a broken ceramic insulator.
→ The cables must not be twisted or kinked when the sensors are screwed in. Avoid pulling on the cable and
connector.
→ Cleanliness in the housing of the plug connections is of utmost importance for the oxygen sensor to function
properly. Particles of dirt can impair the function of the oxygen sensor. The connector must therefore be
protected against any and all types of soiling.
→ Sensors with a soiled or damaged connector must no longer be used.
→ Protect the cables and plugs when carrying or moving the exhaust system with the sensors already fitted.
→ High-pressure cleaning equipment must not be used in the area of the sensors and plug connections.
→ Contact and corrosion agents, e.g. Stabilant, must not be applied to the plug contacts of the oxygen
sensors.
ATTENTION
Danger of injury from heavy loads!
→ When working on the exhaust system, it must be appropriately secured against falling or lowering.
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ATTENTION
Engine exhaust gas!
Danger of poisoning!
→ Only operate the engine with an appropriate exhaust gas extraction system.
ATTENTION
Danger of burns from very hot components (turbocharger, exhaust manifold)!
Note
After the connecting clamps in the exhaust system have been released, they must always be replaced.
During assembly work on the exhaust system, ensure that the components are aligned and installed
correctly.
ATTENTION
High-voltage ignition system!
Danger of electric shocks!
This can cause cardiac irregularities.
→ When working on the ignition system, the ignition key must be removed from the ignition lock.
→ The ignition system must be disconnected from the power supply before starting work on it.
→ Only connect/disconnect lines or plugs when the ignition is switched off.
→ Only connect measuring devices when the ignition is switched off.
Note
The ignition system must be disconnected from the power supply before starting work on it.
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Securing engine on assembly support Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
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DANGER
Suspended load!
Risk of serious crushing and injury
DANGER
Danger of injury from incorrect use of tools and from falling loads!
Danger of crushing from heavy loads!
→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ Never use defective lifting equipment (bent or damaged tools must not be used or repaired. Always replace
these tools). Check tools for signs of damage before use.
→ Only use lifting equipment tested and approved by Porsche. Home-made and auxiliary constructions result
in improper use and are dangerous.
→ The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e.g. from
chains or cables) will damage the transport eyebolt, which must then be replaced. Extreme cases of
improper use can break the transport eyebolt.
→ Tools and lifting equipment must always be used properly. Improper use or dangerous home-made
constructions can break tools and result in falling loads.
→ Wear protective gloves.
Note
Some repair jobs involve suspending the engine on a suitable assembly support.
1. Secure engine support P 9676 on engine → Crankcase on engine support (shown with lower part of
crankcase) . To do this, use the four screws for mounting elements 9590 and tighten them slightly. Secure
engine on engine support. To do this, carefully guide the engine support axle into the take-up bore on the
engine support and secure it.
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Determining the operating cycle of cylinder 1 Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Determining the operating cycle of cylinder 1 with the "cylinder pipe" dead centre finder.
ATTENTION
Risk of damage to timing drive mechanism!
Never twist the crankshaft against the direction of rotation.
Remove and install the chain tensioner only in overlapping TDC.
Never twist the crankshaft when the chain tensioner is removed.
Never twist the camshafts when the chain tensioner is removed.
Never apply forces across the camshafts in the timing drive mechanism.
Always counter the sprocket wheels when performing assembly work on them.
→ Forces from the valve drive can cause the timing chain to jump over or tilt.
Note
An alternative method for determining the overlapping TDC is the "cylinder pipe" (dead centre finder). This tool is
part of the pressure-loss tester WE 1066, Workshop Installation Manual 3.1.4.
For some tasks, it is necessary to be familiar with the position of the piston in the cylinder (ignition TDC,
overlapping TDC).
1. Remove spark plugs for the relevant cylinder 3.→ 287055 Replacing spark plugs
2. The dead centre finder or "cylinder pipe" consists of glass tubes (inspection glass) with pistons -1- , a hose
and a rubber taper -2- .
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Note
This method only works in ignition rod modules that have rubber seals facing the spark-plug recess.
1. Remove spark plugs for the relevant cylinder 3.→ 287055 Replacing spark plugs
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Determining the operating cycle of cylinder 1 Page 4 of 6
2. Find ignition TDC of cylinder 1. To do this, insert the ignition rod module of the first cylinder into the
corresponding opening in the valve cover and press in firmly.
3. Twist the crankshaft in the direction of motion until the ignition rod
module comes out again with an audible plop.
Note
If the crankshaft is then turned through 180°, the piston in cylinder 1 will be located in the bottom dead centre
(BDC). The emission cycle then follows.
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Determining the operating cycle of cylinder 1 Page 5 of 6
4. Then twist the crankshaft until the fixing bore on the crankshaft belt pulley is aligned with the bore in the
timing case cover. The engine is now located in the ignition TDC of cylinder 1.
Note
This method only works in ignition rod modules that have rubber seals facing the spark-plug recess.
1. Remove spark plugs for the relevant cylinder 3.→ 287055 Replacing
spark plugs
V8 spark plugs
2. Find overlapping TDC of cylinder 1. To do this, insert the ignition rod
module of the first cylinder into the corresponding opening in the valve
cover and press in firmly.
4. Then twist the crankshaft until the fixing bore on the crankshaft belt pulley is aligned with the bore in the
timing case cover. The engine is now located in the ignition TDC of cylinder 1.
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Note
If the crankshaft is then turned through 180°, the piston in cylinder 1
will be located in the bottom dead centre (BDC). The compression
cycle then follows.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Tightening torques for Cayenne S (M48/00) and Cayenne Turbo (M48/50) Page 2 of 14
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Information
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Tightening torques for Cayenne S (M48/00) and Cayenne Turbo (M48/50) Page 3 of 14
V8 engine
Note
This torque list is organised according to component groups in the same way as service numbering.
The tightening sequences are indicated in the figures in the corresponding chapters, and it is essential to
observe them.
The most important torques are specified at the end of the respective chapters.
The torques in the table below generally apply to screws which are not specifically listed.
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Tightening sequences
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Tightening sequences
Note
The exterior fastening screws must have a quality of 10.9.
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Group 17 - Lubrication
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Group 19 - Cooling
Tightening sequences
Thermostat housing
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Water pump
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Tightening sequences
Suction module
Tightening sequences
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Exhaust manifold
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Special tools
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Suspending device
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1. Remove design cover from cylinder bank 5-8. To do this, loosen the
four fastening screws -arrows- on the design cover.
Fastening screws
2. Lift the cover slightly with both hands at the side pointing towards the
intake system until it is released from its holder.
Unclipping cover
3. Lift the front of the design cover and remove it.
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DANGER
Suspended load!
Risk of serious crushing and injury
DANGER
Danger of injury from incorrect use of tools and from falling loads!
Danger of crushing from heavy loads!
→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ Never use defective lifting equipment (bent or damaged tools must not be used or repaired. Always replace
these tools). Check tools for signs of damage before use.
→ Only use lifting equipment tested and approved by Porsche. Home-made and auxiliary constructions result
in improper use and are dangerous.
→ The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e.g. from
chains or cables) will damage the transport eyebolt, which must then be replaced. Extreme cases of
improper use can break the transport eyebolt.
→ Tools and lifting equipment must always be used properly. Improper use or dangerous home-made
constructions can break tools and result in falling loads.
→ Wear protective gloves.
Note
Place a cloth between the secondary air pump bracket and design cover to avoid scratching the cover.
Note
Never use defective lifting equipment (bent or damaged tools must not be used or repaired -3- . Always
replace these tools). Check tools for signs of damage before use.
The transport eyebolt must only be pulled straight -1- . Never use side or transverse force on the transport
eyebolt -2- because this can damage the transport eyebolt.
1. Screw transport eyebolt 9700 hand-tight as far as you can into the opening on cylinder head 5 - 8 -arrow- .
2. Insert an M10 screw through the torque support bracket and secure it with a nut. Then attach the hooks of
the suspending device 3033 on both sides → Engaging torque support bracket → Engaging transport
eyebolt after screwing it in . Align the suspending device so that it only pulls the transport eyebolt. To do this,
adjust the spindles of the hooks in such a way that the suspending device 3033 is suspended as
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Suspending device
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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WARNING
Danger of injury from falling loads!
Drive line components (engine, transmission, etc.) can fall down.
→ Before starting work, check the body for structural damage (accident, corrosion, etc.). The load capacity of
the wing mounting points must not be restricted.
→ Do not apply excessive force (e.g. a high screw torque) to supported units.
→ Units must not be supported on the body over an extended period of time.
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DANGER
Danger of injury from incorrect use of tools and from falling loads!
Danger of crushing from heavy loads!
→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ Never use defective lifting equipment (bent or damaged tools must not be used or repaired. Always replace
these tools). Check tools for signs of damage before use.
→ Only use lifting equipment tested and approved by Porsche. Home-made and auxiliary constructions result
in improper use and are dangerous.
→ The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e.g. from
chains or cables) will damage the transport eyebolt, which must then be replaced. Extreme cases of
improper use can break the transport eyebolt.
→ Tools and lifting equipment must always be used properly. Improper use or dangerous home-made
constructions can break tools and result in falling loads.
→ Wear protective gloves.
Note
Never use defective lifting equipment (bent or damaged tools must not be used or repaired -3- . Always
replace these tools). Check tools for signs of damage before use.
The transport eyebolt must only be pulled straight -1- . Never use
side or transverse force on the transport eyebolt -2- because this can
damage the transport eyebolt.
Note
The engine must be supported on the body for some repair work on
the front axle and engine bearings.
Note
When setting up the suspending device, make sure not to scratch or
damage adjacent components.
2. 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.
4. Screw transport eyebolt 9700 hand-tight as far as you can into the opening on cylinder head 5 - 8 → Bore
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5. Position the suspending device on the inner side of the wing, near the radiator tank, and align it. Then tighten
the two wing nuts.
Note
Place a cloth between secondary air pump bracket and design cover to avoid scratching the cover.
7. Insert an M10 screw through the torque support bracket and secure it with a nut. Then attach the hook of the
safety device 10-222 A. If the hook is too short, lengthen it with a suitable spring hook or chain → Fastening
to torque support bracket . Tighten wing nut. Pull the engine slightly and make sure that the force is
distributed evenly on both spindles → Complete view of engine support on body .
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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(Special) tools required for repairing the M48/00 and M48/50 engines Page 2 of 13
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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(Special) tools required for repairing the M48/00 and M48/50 engines
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Tools overview 1
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-7- Safety device 10-222 A See Workshop Equipment For supporting the body
Manual 2.2.3
-8- Spacer 9609/2 See Workshop Equipment Required to fit the radial shaft seal on
Manual 2.2.2 the flywheel
-9- Assembly sleeve 9701 See Workshop Equipment For positioning the sealing lip on the
Manual 2.2.2 camshaft switch-over valve
-10- Camshaft guide 9678 See Workshop Equipment For adjusting the timing
Manual 2.2.2
-11- Locating pin 9595 See Workshop Equipment For fixing the pulley. The piston is then
Manual 2.2.2 in the TDC
-12- Relay puller 9235 See Workshop Equipment For removing the camshaft switch-over
Manual 2.2.2 valve
-13- Arm bracket 9679 See Workshop Equipment Required to loosen the pulley
Manual 2.2.2 fastening.
-14- Bonnet stay 9704 See Workshop Equipment Facilitates the vertical raising of the
Manual 2.2.2 bonnet
-15- Chain pipe cutters NR.166 See Workshop Equipment For disconnecting the exhaust system
Manual 2.4
-16- Flexible screwdriver a/f 7 See Workshop Equipment For loosening and tightening hose
NR.73-1 Manual 2.4 clamps
-17- Antifreeze protection and battery See Workshop Equipment For checking antifreeze contents, acid
acid tester Manual 3 density and windscreen cleaner
-18- Circlip pliers for spring band See Workshop Equipment For opening and loosening spring-band
clamps, Cayenne hose Manual 2.4 clamps
connections NR.72-1
-19- 56-piece Torx screw tool set See Workshop Equipment Required for all assembly work on the
NR.49-1 Manual 2.4 vehicle
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Tools overview 2
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-24- Oil filter spanner 9204 See Workshop Equipment For unscrewing and
Manual 2.2.2 tightening the oil filter
-25- Slide hammer kit NR.168 See Workshop Equipment For pulling out the
Manual 2.4 crankshaft sealing
ring on the flywheel
side
-26- Toothed segment 9538/1 See Workshop Equipment For fixing the
Manual 2.2.2 flywheel
-27- Multiple-tooth socket wrench insert M12 See Workshop Equipment For loosening the
NR.31 Manual 2.4 flywheel
-28- Drift punch, 1 mm tip, NR.167 See Workshop Equipment For perforating the
Manual 2.4 crankshaft sealing
ring on the flywheel
side
-29- Socket-wrench insert with recommended size See Workshop Equipment For removing and
→ 159121 Removing cover for camshaft housing Manual 2.4 installing the
camshaft housing
cover
-30- Plug 9710/3 See Workshop Equipment For checking the
Manual 2.4 exhaust system for
leaks
-31- Engine support 9676 See Workshop Equipment For attaching the
Manual 2.4 engine to the
assembly support.
-32- Engine unit elevating platform WE 1206 See Workshop Equipment
Manual 3.0.13
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
In order to replace the old, removed engine with a new one, some re-fitting work must be done.
Starting point for re-fitting work: old engine is secured to assembly support and the new one is in the
transport cradle.
At higher mileages, components (cooling hoses, clips etc.) must be checked for damage and, if necessary,
replaced.
1. Remove numerous transport plugs for water and vacuum connection pieces of the new engine.
2. Check that all leads and hoses between the engines have been re-fitted and no component has been
forgotten.
3. Depending on the transmission version, the drive plate → 136319 Removing and installing drive plate for
torque converter [9PAAE1 9PAAF1 9PAAJ1]→ 136319 Removing and installing drive plate for torque
converter [9PAAE7] or flywheel → 136019 Removing and installing flywheel [9PAAE7]→ 136019 Removing
and installing flywheel [9PAAE1 9PAAF1 9PAAJ1] must be re-fitted.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove wire harness for engine. → 975219 Removing and installing wire harness for engine - section on
"Removing" [9PAAE1 9PAAE7]→ 975219 Removing and installing wire harness for engine - section on
"Removing" [9PAAF1 9PAAJ1]
3. Remove the generator. → 272219 Removing and installing generator - section on "Removing" [9PAAE1
9PAAE7]→ 272219 Removing and installing generator - section on "Removing" [9PAAF1 9PAAJ1]
4. Remove power-steering pump. → 489819 Removing and installing hydraulic pump (Cayenne
Turbo/Cayenne S) - section on "Removing"
5. Remove left additional assembly bracket -2- and right engine carrier -8- . There are still two dowel sleeves
(not shown) on the additional assembly bracket.
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6. Remove starter. → 276019 Removing and installing starter - section on "Removing" [9PAAE1 9PAAE7
9PAAF1]→ 276019 21 Removing and installing starter - section on "Removing" [9PAAJ1]
7. Remove knock sensors. → 287219 Removing and installing knock sensor - section on "Removing"
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9. Remove water pump. → 195019 Removing and installing coolant pump - section on "Removing"
10. Remove coolant regulator. → 195819 Removing and installing coolant regulator (thermostat) - section on
"Removing"
12. Remove crankshaft. → 134819 Removing and installing crankshaft - section on "Removing"
13. Remove oil spray jets on turbo engine and cap on naturally aspirated engine. → 101321 Removing oil spray
jets for piston cooling [9PAAF1 9PAAJ1]→ 101321 Removing oil spray jets for piston cooling [9PAAE1
9PAAE7]
Information
Component overview
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1- Crankcase, top
2- Closure cap
3- Seal
4- Closure cap
5- Screw → Tightening torque: 10 (7.5 ftlb.) Nm
6- Screw plug → Tightening torque: 10 (7.5 ftlb.) Nm
7- Sealing ring
8- Sealing ring (not marked in illustration)
9- Screw plug → Tightening torque: 75 (56 ftlb.) Nm
10 - Oil spray jets on turbo engine and cap on naturally aspirated engine
11 - Dowel sleeves
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Replacing crankcase
Replacing crankcase
ATTENTION
Risk of damage to cylinder liners on new crankcase if the old pistons are used.
Piston separation could cause the dimensions of the old piston to be unacceptably large compared
with the new cylinder bore.
Risk of piston and cylinder-liner scoring if old, worn pistons are used.
→ The piston rings on the pistons must always be replaced when replacing the crankcase.
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
Note
The bearing shells of the main and connecting-rod bearings must be replaced on vehicles with high mileage.
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Coolant pipe
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Coolant guide
1 - Distributor pipe
2 - Temperature sensor
3 - Sealing ring
4 - Screw plug → Tightening torque: 30 (22 ftlb.) Nm
5 - Fastening screws on distributer pipe → Tightening torque: 10 (7.5 ftlb) Nm
6 - Gasket; replace
7 - Sealing ring; check and replace if necessary
8 - Coolant pipe
3. Re-fit crankcase. When doing so, watch out for dowel sleeves and studs.
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Subsequent work
Subsequent work
1. Assemble engine. → Assembling engine
2. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Testing pressure loss from the engine Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Spark plugs
2. Position cylinder to be tested to ignition TDC and remove tool. There
are two ways of ascertaining the compression cycle in V8 engines
with sealed-off ignition rod modules. → Determining the operating
cycle of cylinder 1
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Testing pressure loss from the engine Page 3 of 6
Information
Test evaluation
The test does not show any meaningful result on a new engine (i.e. one that hasn't been run in).
A difference in pressure loss between the individual cylinders of approx. 5% is not significant.
If the test shows an excessive loss of pressure (> 30%), a few drops of oil can be sprayed into the
combustion chamber. Repeat the test. If the loss in pressure is now significantly less, the seal between the
piston and cylinder is damaged.
The air that is escaping causes hissing noises, which provide information about the component that is
causing the damage.
If the limit values are exceeded, the engine must be started and the test repeated.
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ATTENTION
Danger of damage or injury if pressure loss tester is operated incorrectly
→ Ensure that operational steps and tips from the tool instruction manual for the Bosch tester are observed at
all times.
WARNING
Danger of injury!
The crankshaft can turn because of the pressure in the cylinder.
Note
The check for loss of pressure can be used to assess the mechanical condition of a combustion engine.
The percentage leakage quantity can be used to establish whether the leaks in the combustion chamber in
question are so large that the combustion chamber must be repaired.
The worn components (e.g. piston rings) can be identified by the compressed air that is escaping.
1. Screw in the test hose by hand into the spark plug thread and tighten it by hand.
2. Connect the pressure loss tester to the compressed air system.
3. Adjust the scale. To do this, insert the test nozzle at the front into the device.
4. Turn the adjusting wheel until the scale pointer is at the "cal." marking or "23%". The pressure is then equal
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Adjusting wheel
in the two test chambers of the tool.
5. Remove test hose and check that the pointer falls back. Connect the
test hose. The value that is displayed should not be greater than
30%. If the loss in pressure is greater, it can be assumed that the
engine needs an overhaul.
6. Interrupt the compressed air supply and unscrew the test hose.
Firing order: 1 - 3 - 7 - 2 - 6 - 5 - 4 - 8
Check for loss of pressure
Subsequent work
Subsequent work
1. Remove the test hose once the test is complete and install the spark plugs. For tightening torques see
→ 287055 Replacing spark plugs
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Spark plugs
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\101802_0.htm 5/19/2011
Checking compression of cylinders Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Open the bonnet.
2. Open lid of central electrics box. To do this, loosen the four fastening screws.
WARNING
Risk of electric shocks from high-voltage ignition system and danger of damage to ignition rod modules!
Connected ignition rod modules can be damaged.
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ATTENTION
Risk of damage to components that affect the exhaust system!
Unburnt injected fuel enters the exhaust system.
Spark plugs
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Information
Note
A test document is created when a compression test is performed.
In order to prevent misuse, vehicle ID, date and current mileage must be entered.
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Test sheet
Note
The compression test can only provide an indication as to whether the tested cylinder is working or not working
properly. The cause of any loss can be further isolated by a pressure loss test.→ 101802 Testing pressure loss
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Checking compression of cylinders Page 6 of 7
Note
Once the starter is activated, it switches on the engine for approx.
seven seconds.
The vehicle voltage must not drop below 12 V during the test.
The throttle must always remain in the same position throughout the
Pressure tester
test. A mechanical pressing-on tool is not permitted.
2. Have the starter actuated by a second person. Testing of this cylinder is complete when the needle of the
test device ceases to rise. Keep the accelerator pedal fully depressed.
4. Move the scale on to another cylinder. To do this, pull the pin once
under the handle on the back → Moving the test device on by one
cylinder .
Subsequent work
Subsequent work
Spark plugs
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Checking compression of cylinders Page 7 of 7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\101902_0.htm 5/19/2011
Removing and installing engine carrier Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Support engine on the body.→ Supporting engine on the body.
2. Remove engine guard. → 108019 Removing and installing engine guard - chapter on "Removing"
3. Remove front axle until the engine carrier can be removed. → 400619 Removing and installing front-axle
carrier - chapter on "Removing" [9PAAJ1]→ 400619 Removing and installing front-axle carrier - chapter on
"Removing" [9PAAE1 9PAAE7 9PAAF1]
Information
Component overview
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Component overview
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WARNING
Danger of injury!
→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ Never use defective lifting equipment.
→ Only use lifting equipment tested and approved by Porsche.
→ The components are very heavy. There is a danger of crushing.
→ Wear protective gloves.
→ Please observe general warning notes.
Note
This task can only be performed if the engine has been removed or suspended on the body.
Note
Do not undo the engine mounts on the engine.
If the engine mounts have been undone on the engine, they must be aligned using the engine carrier.
→ 103519 Removing and installing engine mount
Engine carrier
1. Undo the two fastening screws → Fastening screws for engine mounting to the left and right on the hydraulic
mounts.
2. Undo the two fastening screws from the engine carrier to the body and remove the engine carrier.
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Subsequent work
Subsequent work
1. Screw in new fastening screws for securing the engine carrier to the body. → Initial tightening: 89 ftlb. →
Torque angle: 180 °
2. Install front axle. → 400619 Removing and installing front-axle carrier - chapter on "Installing" [9PAAJ1]
→ 400619 Removing and installing front-axle carrier - chapter on "Installing" [9PAAE1 9PAAE7 9PAAF1]
3. Install engine guard. → 108019 Removing and installing engine guard - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Support engine on the body.→ Supporting engine on the body.
2. Remove engine guard. → 108019 Removing and installing engine guard - chapter on "Removing"
3. Remove front axle until the engine carrier can be removed. → 400619 Removing and installing front-axle
carrier - chapter on "Removing" [9PAAJ1]→ 400619 Removing and installing front-axle carrier - chapter on
"Removing" [9PAAE1 9PAAE7 9PAAF1]
Information
Component overview
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Component overview
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WARNING
Danger of injury!
→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ Never use defective lifting equipment.
→ Only use lifting equipment tested and approved by Porsche.
→ The components are very heavy. There is a danger of crushing.
→ Wear protective gloves.
→ Please observe general warning notes.
Note
This task can only be performed in the Cayenne S (M48/00) if the engine has been removed or suspended
on the body. This description covers suspension on the body.
1. Undo the two fastening screws -Arrows- to the left and right on the
hydraulic mounts.
Hydraulic mount
2. Undo the two fastening screws from the engine carrier to the body
and remove the engine carrier. -Centre arrow-
Engine carrier
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Note
The engine mounts must be aligned using the engine carrier.
1. Position engine mounts on the support arm. When doing so, note the positioning pin on the mount. It must
engage in the recess on the support arm.
2. Position new fastening nuts and screw them on so that the positioning pin cannot pop out. Do not tighten the
fastening nuts.
Subsequent work
Subsequent work
1. Screw in new fastening screws for securing the engine carrier to the body. → Initial tightening: 89 ftlb. →
Torque angle: 180 °
2. Install front axle. → 400619 Removing and installing front-axle carrier - chapter on "Installing" [9PAAJ1]
→ 400619 Removing and installing front-axle carrier - chapter on "Installing" [9PAAE1 9PAAE7 9PAAF1]
3. Install engine guard. → 108019 Removing and installing engine guard - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Overview
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Removing and installing engine guard Page 3 of 4
1. Remove front engine guard. To do this, loosen the screws -1- at the
front and side. Then loosen the rear -2- and front screws -3- .
Front screws
2. Remove rear engine guard. To do this, loosen the fastening screws on the transmission cross member -1-
and the screws on the traverse strut -2- .
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Rear screws
Installing engine guard
1. Install the rear engine guard. To do this, screw in the front fastening
screws -2- and rear fastening screws -1- .
2. Tighten front fastening screws -3- and rear fastening screws -2- and
-1- → Tightening torque: 6.5 ftlb. .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Overview
Note
A special paint is applied to the covers for reasons of appearance.
When the engine is washed, a minimum clearance of 50 cm must be maintained between the cleaning
apparatus lance and the covers.
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Small scratches on the paintwork can be touched up with a special touch-up applicator.
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Note
Place a cloth between secondary air pump bracket and design cover to avoid scratching the cover.
1. Remove engine compartment cover on the right and rear. → 700219 Removing and installing front cover
(engine compartment)
4. Detach 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.
5. Unscrew the four fastening screws on the design cover (picture shows side 5 - 8).
6. Remove design cover from cylinder bank 1 - 4. Lift the cover slightly with both hands on the edge pointing
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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.
Note
Place a cloth between secondary air pump and design cover to avoid scratching the 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.
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Note
Place a cloth between secondary air pump bracket and design cover to avoid scratching the cover.
1. 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. Tighten the four fastening screws on the ignition coils (illustration shows side 5-8). → Tightening torque:
3.5 ftlb.
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6. Screw in the fastening screw securing the torque support to the body
(M10 x 70). → Tightening torque: 44 ftlb.
7. Install engine compartment cover on the right and rear. → 700219
Removing and installing front cover (engine compartment)
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. Screw in the four fastening screws at the ignition coils → Tightening torque: 3.5 ftlb.
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing pistons Page 2 of 9
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Information
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Component overview
Identification of pistons
Note
Pistons are installed as standard in three dimensional groups: I, X and II.
Piston marking
Pistons are installed as standard in two weight tolerances: + and -.
These data are all engraved on the piston crown. To uniquely identify a piston, it must be carefully cleaned (brass
brush, ultrasonic bath). If, in spite of very thorough cleaning, the data are unreadable, the piston must be weighed
together with piston rings, piston pin and the two circlips. Thorough cleaning (ultrasonic bath) is also absolutely
essential to the weighing operation as otherwise the measurement result will be false.
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1. A piston removed for repair is cleaned and identified. If it needs to be replaced, an X - piston with the
identified weight tolerance + or - is ordered as a replacement part and installed.
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
Removing pistons
Removing pistons
Note
Connecting rod bolts and bearing shells must always be replaced.
Turn the crankshaft so that the crank pin of the piston to be removed
stands vertically upwards.
2. Remove one piston after another, mark them and place them on a
clean tray. The arrow on the bottom of the piston points in the
Holding bridges at bearings 3 and 5
direction of travel.
5. Press the piston downwards out of the cylinder, for example with the handle of a hammer, and receive it with
the other hand.
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6. Fit the connecting-rod bearing cap again immediately on the big end of the connecting-rod bearing with the
bearing shells and place the entire piston on a clean surface.
7. Mark piston with No. 1 (with a felt-tip, not with a prick punch or other sharp-edged tool).
Note
Note the association between the connecting-rod big end and the
connecting-rod bearing cap as the cracked connecting rods only fit in
one position.
The connecting-rod bearing cap and the big end of the connecting-rod
bearing have the same connecting-rod numbers. Retaining lugs of connecting-rod
bearings
Note
Note the association between the connecting-rod big end and the
connecting-rod bearing cap as the cracked connecting rods only fit in
one position.
The connecting-rod bearing cap and the big end of the connecting-rod
bearing have the same connecting-rod numbers. View of connecting rod numbers
Installing pistons
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Installing pistons
Note
Connecting rod bolts and bearing shells must always be replaced.
The identification of the connecting-rod bearings is located on the connecting-rod journal of the crankshaft →
Removing and installing crankshaft.
Note
The pistons must already be pre-fitted (pistons, piston rings, connecting rods and fastening material) before
performing the next step. → 131037 Disassembling and assembling pistons - chapter on "assembling"
Install with the number on the connecting rod -A- to the exhaust side.
When installing the piston in the crankcase, the direction of travel arrow on the piston crown must point in the
direction of travel.
Allocation
The direction of travel arrow must be pointing forwards when installed (in direction of travel).
1. Turn the engine in the engine support so that the crankshaft lies at the bottom.
2. Install piston. To do this, turn the crankshaft with a wrench (a/f 27) until the corresponding crank pin is
pointing vertically downwards.
3. Cylinder, piston and Piston ring restraining strap for 944 - S2 and Boxster and 911 Carrera (996) NR.57
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Installing pistons
6. Push piston downwards until the connecting-rod bearing sits on the
crank pin. If necessary, use the handle of a hammer to push it
-see figure- .
Note
The piston connecting rods are cracked and only fit in one position (in
conjunction with the matching numbers).
Pressing in piston
Install con-rod code towards exhaust side -A- .
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11. Turn crankcase on the assembly support until the crankshaft is on top.
12. Tighten con-rod bolts that have been replaced. Turn the crankshaft
until the corresponding crank pin is pointing vertically upwards.
Tighten bolts with a multiple-tooth socket → Initial tightening 1: 6
ftlb. → Initial tightening 2: 15 ftlb. → Initial tightening 3: 30 ftlb. →
Torque angle (final tightening): 90 ° .
Subsequent work
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3. Install oil pan → 175023 Oil pan installed (including seal) - section on "Installing"
5. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
Piston disassembly
Tools
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-B- Assembly aid 9500/3 → "See Workshop For pre-fitting the piston-pin
Equipment Manual, circlip in the assembly sleeve
Chapter 2.2.2"
-C- Assembly sleeve 9500/9 → "See Workshop For fitting the piston pin circlip
Equipment Manual, in the correct position
Chapter 2.2.2"
-D- Plunger 9500/8 → "See Workshop For fitting the piston pin and
Equipment Manual, piston pin circlip
Chapter 2.2.2"
-E- Piston ring pliers 58 → "See Workshop
Equipment Manual,
Chapter 2.4"
Information
Component overview
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Identification of pistons
Note
Pistons are installed as standard in three dimensional groups: I, X and II.
Piston marking
Pistons are installed as standard in two weight tolerances: + and -.
These data are all engraved on the piston crown. To uniquely identify a piston, it must be carefully cleaned (brass
brush, ultrasonic bath). If, in spite of very thorough cleaning, the data are unreadable, the piston must be weighed
together with piston rings, piston pin and the two circlips. Thorough cleaning (ultrasonic bath) is also absolutely
essential to the weighing operation as otherwise the measurement result will be false.
1. A piston removed for repair is cleaned and identified. If it needs to be replaced, an X - piston with the
identified weight tolerance + or - is ordered as a replacement part and installed.
Disassembling pistons
Disassembling pistons
Note
If reusing a piston, do not remove combustion residues on the piston crown are mechanically!
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Note
When disassembling the piston/connecting rod unit, note or mark the position, relationship to cylinder and
installation position using a waterproof felt tip pen.
ATTENTION
Engine damage if piston rings overstretched!
→ Do not overstretch piston rings with piston ring pliers. Spread the
piston ring until it just fits over the piston.
Piston pin with plunger
5. Remove piston rings. Place the piston on a clean surface and look for the gaps in the piston rings.
Note
Compression rings and oil scraper rings are installed and removed differently.
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6. Remove the piston rings starting from the piston crown. To do this, move the middle point of piston ring
pliers Gr. 1 NR.58 into the gap in the relevant ring. The holding arms of the piston ring pliers should clasp
the piston ring from above → Piston ring pliers on piston ring . Only open the piston ring as much as is
needed to remove the piston ring from the groove. Do not overstretch it!
7. Relieve the piston ring pliers and remove the piston ring from the pliers.
8. Remove the three-piece oil scraper ring as follows: First, remove the upper and lower rings by hand by
carefully forcing them away from the piston. Then remove the oil scraper spring carefully in the same way.
Assembling pistons
Assembling pistons
1. First assemble the three-piece oil scraper ring. To do this, carefully stretch the oil scraper spring by hand at
its gap to a point where this can be positioned over the piston in ring groove 3. Carefully force apart a ring in
the oil scraper ring by hand and fit it into the third piston ring groove below the oil scraper spring. Fit the
second ring in the same way over the oil scraper spring.
2. When fitted, the gap in the oil scraper ring must be offset by exactly 180° with respect to the gap in the oil
scraper spring. Make sure that the oil scraper spring is in the middle of the oil scraper ring.
Note
The two compression rings have different strengths and can only be
installed in the appropriate groove.
If the piston ring has the inscription TOP, this must point to the piston
crown.
3. Insert piston ring into the piston ring pliers. Make sure that, when
installed, the designation of the piston rings is pointing in the
direction of the piston crown -A- . Spread the piston ring until it just
fits over the piston. Piston ring designation
4. Fit piston rings. Using the piston ring pliers, insert the middle piston ring into the second ring groove in such
a way that the inscription TOP is facing the piston crown. Insert the top piston ring into ring groove 1 in such
a way that the inscription TOP is facing the piston crown.
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5. Check that the piston rings are correctly seated and positioned. Make sure that the oil scraper spring is
inside the oil scraper ring. In the case of the piston ring in ring groove 2, the inscription TOP must point to the
piston crown. The top piston ring must be installed in such a way that the inscription TOP is facing the piston
crown. The gaps in the individual piston rings must always be offset by 120°.
11. Fix piston on retaining device 9597 with fitted piston-pin circlip facing downwards → Piston on retaining
device .
12. Gap of circlip must point downwards away from the piston crown (analogous to 6 o'clock, alternatively 11
o'clock). Place piston pin and connecting rod in installation position. Align connecting rod with matching
number so that the matching numbers point to the exhaust side -A- . Illustration shows direction of travel in
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Allocation
this case and connecting rod code on one side.
13. Fit oiled piston pin through the piston and connecting-rod eye as far
as the circlip. Using a plastic hammer, tap gently on plunger 9500/8,
driving the piston pin into the pre-fitted piston-pin circlip -arrow- .
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Note
The connecting rods are cracked and together with the matching
numbers cannot be mixed up!
16. Fit connecting-rod bearing shells in connecting-rod big end and Position of bearing shells
connecting-rod bearing cap. The retaining lugs must be positioned in
the appropriate grooves and on the same side -B and C- . The
matching numbers -A- must be the same and on the same side
(when installed they point to the exhaust side). Tighten the
connecting rod bolts by hand and position the complete connecting
rod ready for assembly.
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
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Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
3. Remove oil pan. → 175019 21 Removing and installing oil pan - section on "Removing"
4. Remove oil pump. → 172019 Removing and installing oil pump - section on "Removing"
Removing crankshaft
Removing crankshaft
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1 - Crankshaft
2 - Straight pin
3 - Feather key
4 - Thrust washer, insert with grease no. 000.043.204.17
5 - Upper crankshaft bearing shell, lubricate with motor oil
6 - Lower crankshaft bearing shell, lubricate with motor oil
7 - Radial shaft sealing ring, crankshaft
H - Main bearing, location of colour dots
P - Connecting rod bearing, location of colour dots
Note
The colour codes of the crankshaft bearings and bearing shells must match!
To ensure that the bearings and bearing shells are of a matching class during installation, the bearing
numbers are to be written on the backs of the bearings during removal of the main bearing shells with a
waterproof felt-tipped pen, due to that fact that the ink markings wear off of the crankshaft journals as well as
the main bearing shells.
New bearing shells are always to be installed when the engine is repaired.
Crankshaft
Main bearing shells Red yellow Blue
+ connecting-rod
bearing shells Red X
yellow X
Blue X
2. Unscrew the four hexagon socket head bolts on the clutch side (M8). → Clutch side
3. Unscrew the outer cross bolt connection (M8 x 70) in the opposite order to the sequence shown.
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4. The figures below indicate the tightening sequence. The fastening screws are undone in the opposite order
to the tightening sequence shown.. → Outer bearing seat
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5. Undo inner bearing seat in the opposite order to the tightening sequence shown. → Inner bearing seat
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7. Remove any remaining sealant and the old sealing ring in the upper part of the crankcase.
ATTENTION
Danger of crushing!
Risk of crushing your hands when lifting the crankshaft.
10. Undo holding bridges 9677 and carefully remove crankshaft upwards.
Installing crankshaft
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Installing crankshaft
Note
If no clear markings can be seen after thorough cleaning of the crankshaft and the bearings, the crankshaft
and the corresponding bearing shells are to be replaced.
Note
The bearing shells are available in various tolerance classes. The
classes are indicated by the colour marking on the outside
-refer to Figure- . The colour marking must match the corresponding
colour dot on the crankshaft. The colours are red, yellow and blue
and must match between the bearings and the crankshaft.
New connecting rod bearings main bearing shells are always to be installed when the motor is repaired.
1. Insert the bearing shells with the lubricating groove into the upper part of the crankcase. Make sure the twist
locks are positioned correctly -see figure- . Then lightly oil the bearing locations.
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ATTENTION
Danger of crushing!
Risk of crushing your hands when lifting the crankshaft.
3. Insert crankshaft. The connection flange must point towards the back
of the engine. Then secure the crankshaft from falling down using
holding bridges 9677. Fix the holding bridges at bearing locations 3 Turning the crankshaft
and 5. Screw the fastening screw from the belt pulley at the front into
the crankshaft and tighten slightly so that the crankshaft can be
turned -see figure- .
7. Make sure the crankcase is ready to be screwed in. Check that the sickle discs are positioned correctly.
Degrease parting surfaces between top and bottom section of crankcase. A totally grease-free product (e.g.
brake cleaner) must be used for this. Then insert a new O-ring at the front of the parting surface -3- .
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Centring pins
8. Screw the two thin centring pins 9321 into the outer fastening bores on the upper part of the crankcase
-see illustration (shown without crankshaft)- .
9. Insert bearing shells into lower part of crankcase and lightly oil them.
When doing so, ensure that the twist locks (retaining lugs) fit into the
appropriate recesses in the lower part of the crankcase.
Note
The liquid sealant must be applied and the screws screwed in within
five minutes at most and without interruption.
10. Apply the Drei Bond Silikon 2210 liquid sealant to the lower part of the crankcase as illustrated. The outer
surfaces marked -A- must be cleaned after fitting.
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Sealant application
11. Place bottom section of crankcase into position. When doing so, make sure that the sealing bead is not
destroyed.
Note
Unscrew the centring pins again while securing the lower part of the crankcase.
12. The figures below indicate the tightening sequence. The screws are tightened in four steps. It is essential
that the tightening sequence is observed here. The screws must be tightened within five minutes.
→ Initial tightening: 30 ftlb.
→ Initial tightening: 16 ftlb.
→ Final tightening: 56 °
→ Final tightening: 60 °
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13. Then screw on the outer cross bolt connection (M8 x 70) in the sequence shown → Tightening torque: 17
ftlb. .
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14. Tighten the four hexagon socket bolts on the clutch side (M8 x 35) →
Tightening torque: 17 ftlb. .
Clutch side
15. Fit chain drive sprocket on the crankshaft. Unscrew fastening screw on belt pulley. Check that the feather
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keys are fitted correctly and push on the chain sprocket with the oil pump drive chain → Chain drive wheel .
The double-tooth row must be facing forwards.
Subsequent work
Subsequent work
1. Install oil pump. → 172019 Removing and installing oil pump - section on "Installing"
5. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
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Preliminary work
1. Remove drive plate or flywheel. → 136019 Removing and installing flywheel [9PAAE7]→ 136019 Removing
and installing flywheel [9PAAE1 9PAAF1 9PAAJ1] or → 136319 Removing and installing drive plate for
torque converter [9PAAE1 9PAAF1 9PAAJ1]→ 136319 Removing and installing drive plate for torque
converter [9PAAE7]
Required tools
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1. Using the tool drift punch (1-mm tip) NR.167, beat a small hole into
a non-rubberised spot (rectangular window in the ring) of the sealing
ring.
Drift punch
2. Screw in the extractor tip. Knock out the extractor tip using slide
hammer kit NR.168 in conjunction with the sealing ring.
ATTENTION
Damage to the sealing ring!
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Centring tool
3. Position the retracting bell and tighten the central screw (a/f 19) to 25
Nm (19 ftlb.).
5. Undo the two fastening screws on the centring device and remove
the tool.
Fitting bell
Subsequent work
Subsequent work
1. Install drive plate or flywheel. → 136019 Removing and installing flywheel [9PAAE7]→ 136019 Removing
and installing flywheel [9PAAE1 9PAAF1 9PAAJ1] or → 136319 Removing and installing drive plate for
torque converter [9PAAE1 9PAAF1 9PAAJ1]→ 136319 Removing and installing drive plate for torque
converter [9PAAE7]
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
Preliminary work
1. Remove transmission. → 373519 Removing and installing transmission - chapter on "Removing" [9PAAJ1]
→ 373519 Removing and installing transmission - chapter on "Removing" [9PAAE1 9PAAF1]
Special tools
Puller
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Toothed segment
2. Unscrew drive plate. To do this, loosen the ten diagonally opposite
fastening screws.
4. If the drive plate is stuck, remove it using an internal puller and slide
hammer.
Drive plate
5. To do this, insert internal puller into the middle of the drive plate and
tighten.
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Slide hammer
Note
Clean the crankshaft stub before installing the drive plate (remove rust).
Toothed segment
3. Tighten the ten new fastening screws crosswise. → Tightening
torque: 44 ftlb. ; then → Torque angle: 90 °
Fastening screws
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Subsequent work
Subsequent work
1. Install transmission. → 373519 Removing and installing transmission - chapter on "Installing" [9PAAJ1]
→ 373519 Removing and installing transmission - chapter on "Installing" [9PAAE1 9PAAF1]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Loosen drive belt around the belt tensioner. → 137819 Removing and installing drive belt - chapter on
"Removing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing drive belt - chapter on
"Removing" [9PAAE1 9PAAE7]
Information
Component overview
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1 - Deflection roller, cylinder bank 1-4 → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
2 - Tensioning roller
3 - Holder for deflection roller
4 - Fastening screw for damper → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
5 - Support for tensioning roller → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
6 - Shock absorber/tensioning element; bellows must be facing upwards. Observe code on the component.
7 - Deflection roller, cylinder bank 5-8 → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
8 - Sheetmetal holder
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Deflection roller
Note
When fitting the shock absorber/tensioning element, ensure that the label can be read from outside.
Subsequent work
Subsequent work
1. Fit drive belt. → 137819 Removing and installing drive belt - chapter on "Installing" [9PAAF1 9PAAJ1]
→ 137819 Removing and installing drive belt - chapter on "Installing" [9PAAE1 9PAAE7]
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing sealing ring for crankshaft belt pulley Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Component overview
-1- - Radial shaft seal (align using the plastic sleeve provided)
-2- - Upper fastening screw
-3- - Lower fastening screw
-4- - Chain tensioner
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Removing and installing sealing ring for crankshaft belt pulley Page 3 of 4
Preliminary work
Preliminary work for removing sealing ring for crankshaft sealing ring
1. Remove pulley (vibration balancer) of the crankshaft → 137619 Removing and reinstalling crankshaft belt
pulley - chapter on "Removing".
1. Undo the 4 fastening screws and remove the cover and sealing ring.
2. Clean the sealing surface of the sheetmetal cover.
WARNING
Risk of damaging the sealing ring due to assembly fault!
Never pull the sealing ring from the plastic sleeve!
Do not touch the sealing lip!
Do not oil the sealing ring on the running surface!
Note
If the joint flange on the pulley or the surface on the crankshaft stub is slightly rusted, polish the rust off with a
special polishing pad.
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Removing and installing sealing ring for crankshaft belt pulley Page 4 of 4
Plastic sleeve
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing crankshaft belt pulley Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing crankshaft belt pulley Page 3 of 6
Preliminary work
2. Loosen drive belt and remove from the pulley. For details see → 137819 Removing and reinstalling drive belt
- chapter on "Removing" [9PAAF1 9PAAJ1]→ 137819 Removing and reinstalling drive belt - chapter on
"Removing" [9PAAE1 9PAAE7].
1. Position arm bracket 96790 in the pulley and turn it until it locks.
ATTENTION
Material damage!
If the tool slips or if the tool is faulty, the wings or the cooling
fan can be damaged as a result of excessive forces!
2. Position a large torque wrench and loosen the central screw. Do not use the screw again.
3. Remove the central screw and pull the pulley down and forward.
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Removing and installing crankshaft belt pulley Page 4 of 6
Note
A key is inserted into the crankshaft. When fitting the pulley, ensure
that the key lies in the groove in the pulley.
1. Position the pulley on the crankshaft stub. Then press the pulley
slightly in the direction of the engine, while at the same time twisting
it until it slips definitively in the direction of the timing-case cover. Pulley on crankshaft stub
When doing so, pay attention to the key.
2. Mount the new central screw hand tight into the crankshaft.
ATTENTION
Material damage!
If the tool slips or if the tool is faulty, the wings or the cooling fan can be damaged as a result of
excessive forces!
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Removing and installing crankshaft belt pulley Page 5 of 6
3. Position arm bracket 96790 in the pulley and turn it until it locks. Have a second worker operate the arm
bracket.
ATTENTION
Material damage!
If the tool slips or if the tool is faulty, the wings or the cooling
fan can be damaged as a result of excessive forces!
5. Push on torque angle disc Mechanical angle disc for torque angle
threaded joint NR.88-1. Attach a magnetic foot to a metal part and
set the scale by turning the pointer to 0. As an alternative to the
torque angle disc, marks can be made on the vibration balancer
(crankshaft pulley) and the central screw using a waterproof pen. A
continuous line between the central screw and vibration balancer
represents the starting point, another line only on the vibration
balancer at an angular distance of 90° shows the torque angle target.
ATTENTION
Material damage!
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Removing and installing crankshaft belt pulley Page 6 of 6
If the tool slips or if the tool is faulty, the wings or the cooling
fan can be damaged as a result of excessive forces!
Subsequent work
Drive belt
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\137619_0.htm 5/19/2011
Checking drive belt Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped
pipe) [9PAAF1 9PAAJ1]→ 243519 Removing and installing cowl for throttle part (Y-shaped pipe) [9PAAE1
9PAAE7]
Information
Information
ATTENTION
Risk of damage to drive belt!
If the drive belt is removed when it is hot, it may become deformed and damaged.
ATTENTION
Consequential damage of broken pulley belt!
Due to a broken drive belt during driving, surrounding components (panelling, electric cables etc.)
can be damaged by thrashing or flying belt parts.
Parts of the drive belt can jam behind deflection rollers or vibration balancers and damage surfaces
and sealing rings there. In particular, the sealing ring of the crankshaft vibration balancer can
become leaky as a result of a broken belt.
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→ Following a belt breakage the surrounding components and the interior of the engine compartment must be
inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration balancer,
deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.
→ The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration
balancers for prior damage.
WARNING
Danger of injury!
The vehicle fans can continue running or start up automatically.
→ The power supply to the radiator fans or the battery must be disconnected before starting to work on the
radiator or fans (remove fuse → fuse carrier [9PAAJ1]→ fuse carrier [9PAAE1 9PAAE7 9PAAF1]).→ Work
instructions after disconnecting the battery
Damage symptoms
Note
The following table indicates damage which necessitates replacement.
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Note
If spark plugs must be changed in the course of maintenance operations, the drive belt should be checked
when the spark plugs are removed. The engine can then be cranked easier.
1. Using chalk, mark the drive belt in the area around the tensioning roller.
2. Turn engine at the vibration damper in the direction of movement using a socket wrench (a/f 27) until the
chalk mark is at the same place again. While turning at the crankshaft, check the belt at the deflection rollers
for signs of damage.
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Subsequent work
1. Fit intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped pipe) [9PAAF1
9PAAJ1]→ 243519 Removing and installing cowl for throttle part (Y-shaped pipe) [9PAAE1 9PAAE7]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing drive belt Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped pipe)
Information
Information
ATTENTION
Risk of damage to drive belt!
If the drive belt is removed when it is hot, it may become deformed and damaged.
ATTENTION
Consequential damage of broken pulley belt!
Due to a broken drive belt during driving, surrounding components (panelling, electric cables etc.)
can be damaged by thrashing or flying belt parts.
Parts of the drive belt can jam behind deflection rollers or vibration balancers and damage surfaces
and sealing rings there. In particular, the sealing ring of the crankshaft vibration balancer can
become leaky as a result of a broken belt.
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→ Following a belt breakage the surrounding components and the interior of the engine compartment must be
inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration balancer,
deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.
→ The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration
balancers for prior damage.
WARNING
Danger of injury!
The vehicle fans can continue running or start up automatically.
→ The power supply to the radiator fans or the battery must be disconnected before starting to work on the
radiator or fans (remove fuse → fuse carrier).→ Work instructions after disconnecting the battery
2. Relieve and remove drive belt. To do this, use an open-ended wrench (a/f 30) to turn the belt tensioner
clockwise and remove the drive belt from the tensioning roller. Relieve the belt tensioner slowly.
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Note
The figure → Drive belt
threading course shows the
complete belt threading
course. The pulleys are
numbered according to the
sequence of fitting.
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1. Make the belt into a loop and place over the crankshaft belt pulley
behind the dipstick.
Deflector wheel
5. Then guide the section of the belt around the air-conditioning compressor belt pulley -4- at the bottom.
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Generator pulley
8. Gather the belt section between the deflection roller of cylinder bank
1 - 4 and the crankshaft pulley to form a loop and guide it upwards to
the tensioning roller -8- . Use a wrench (a/f 30) to turn the tensioning
roller -8- in a clockwise direction at the hexagon and put on the drive
belt. Slowly relieve the tensioning roller.
Tensioning roller
9. Check that the drive belt is positioned correctly on the pulleys.
Subsequent work
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Subsequent work
1. Fit intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped pipe)
9PAAE1, 9PAAE7
as of MY 2003
Country C20, C21, C22, C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46,
C98, C99
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Removing camshaft housing Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove intake-air distributor. → 244601 Checking intake-air distributor for leaks - section on "Removing"
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1 - Camshaft housing
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1. Unscrew the upper fastening screw -3- of oil line. Replace sealing ring -2- .
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2. Unscrew both hexagon socket head bolts M8 x 20 and M8 x 30 on the front end (on cylinder row 1-4, the
screws are located at the side on the exterior of the chain box).
Note
When removing the camshaft housing, ensure that none of the sealing rings or residual sealant fall into the
cylinder head.
3. Unscrew 26 camshaft housing fastening screws M8 x 45 contrary to the indicated order and lever camshaft
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housing off the cylinder head. When removing the camshaft housing, ensure that none of the sealing rings or
residual sealant fall into the cylinder head.
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove intake-air distributor. → 244601 Checking intake-air distributor for leaks - section on "Removing"
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Removing camshaft housing Page 3 of 7
1 - Camshaft housing
2 - Camshaft sensor fastening screw M6 x 16
3 - Camshaft sensor
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4- Plug
5- Cheese head bolt M8 x 20
6- Cheese head bolt M8 x 30
7- Sealant application on camshaft housing. Make sure that no sealant can fall into the cylinder head. Carefully
remove old residual sealing compound.
8 - Camshaft housing securing screw M8 x 45
9 - Sealant application on spark plug recess. Make sure that no sealant can fall into the cylinder head. Carefully
remove old residual sealing compound.
10 - Oil duct sealing ring
2. Unscrew upper fastening screw -3- of oil line. Replace sealing ring -2- .
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Oil strainer
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3. Unscrew both hexagon socket head bolts M8 x 20 and M8 x 30 on the front end (on cylinder row 1-4, the
screws are located at the side on the exterior of the chain box).
Note
When removing the camshaft housing, ensure that none of the sealing rings or residual sealant fall into the
cylinder head.
4. Unscrew 26 camshaft-housing fastening screws (M8 x 45) contrary to the order shown → Tightening
sequence for camshaft housing and lever camshaft housing off the cylinder head. When removing the
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camshaft housing, ensure that none of the sealing rings or residual sealant falls into the cylinder head.
as of MY 2005
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
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1- Camshaft housing
2- Camshaft sensor fastening screw M6 x 16
3- Camshaft sensor
4- Plug
5- Cheese head bolt M8 x 20
6- Cheese head bolt M8 x 30
7- Sealant application on camshaft housing. Make sure that no sealant can fall into the cylinder head. Carefully
remove old residual sealing compound.
8 - Camshaft housing securing screw M8 x 45
9 - Sealant application on spark plug recess. Make sure that no sealant can fall into the cylinder head. Carefully
remove old residual sealing compound.
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Note
Before installing, remove all residual sealing compound and clean sealing surfaces on cylinder head and
camshaft housing!
1. Clean sealing surfaces on camshaft housing and cylinder head using suitable means (e.g. acetone and
cloth).
Note
The sealant application must not be too thick because otherwise excess sealant can enter the cylinder head!
For applying the sealant, there are, amongst other things, two grooves on the front section of the camshaft
housing!
2. Replace oil duct sealing ring on cylinder head and apply a thin bead (approximate width 1.5 mm) of sealing
compound (000 043 300 39, status 12/05) onto the camshaft housing in accordance with -Illustration- .
When doing this, do not forget the sealing surfaces of the spark plug recesses.
3. Place camshaft housing on cylinder head. Position M8 fastening screws and tighten in tightening sequence
→ Tightening sequence for camshaft housing . → Tightening torque: 23 (17 ftlb.) Nm
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Subsequent work
Subsequent work
1. Turbocharged engine (M48/50): Screw down sheetmetal bracket for turbocharger. To do this, tighten the 2
fastening screws → Tightening torque: 23 (17 ftlb.) Nm and screw with new nut → Tightening torque: 30
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Ground connection
4. Secure oil feed line by hand in the camshaft housing with the union
nut and then tighten. → Tightening torque: 35 (26 ftlb.) Nm
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9. Install intake-air distributor. → 244619 Removing and installing intake-air distributor - section on "Installing"
10. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
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1- Camshaft housing
2- Camshaft sensor fastening screw M6 x 16
3- Camshaft sensor
4- Plug
5- Cheese head bolt M8 x 20
6- Cheese head bolt M8 x 30
7- Sealant application on camshaft housing. Make sure that no sealant can fall into the cylinder head. Carefully
remove old residual sealing compound.
8 - Camshaft housing fastening screw M8 x 45
9 - Sealant application on spark plug recess. Make sure that no sealant can fall into the cylinder head. Carefully
remove old residual sealing compound.
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Note
Before installing, remove all residual sealing compound and clean sealing surfaces on cylinder head and
camshaft housing!
1. Clean sealing surfaces on camshaft housing and cylinder head using suitable means (e.g. acetone and
cloth).
Note
The sealant application must not be too thick because otherwise excess sealant can enter the cylinder head!
For applying the sealant, there are, amongst other things, two grooves on the front section of the camshaft
housing!
2. Replace oil duct sealing ring on cylinder head and apply a thin bead (approximate width 1.5 mm) of liquid
sealing compound 000.043.300.39 Loctite 5970 (status 11/2005, for details of currently used sealant, see
Spare Parts Catalogue) onto the camshaft housing in accordance with -Illustration- . When doing this, do
not forget the sealing surfaces of the spark plug recesses.
3. Place camshaft housing on cylinder head. Position M8 fastening screws and tighten according to specified
tightening sequence → Tightening sequence for camshaft housing . → Tightening torque: 23 (17 ftlb.) Nm
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Oil strainer
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Subsequent work
Subsequent work
1. Turbocharged engine (M48/50): Screw down sheetmetal bracket for turbocharger. To do this, tighten the 2
fastening screws → Tightening torque: 23 (17 ftlb.) Nm and screw with new nut → Tightening torque: 30
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Ground connection
4. Secure oil feed line by hand in the camshaft housing with the union
nut and then tighten. → Tightening torque: 35 (26 ftlb.) Nm
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9. Install intake-air distributor. → 244619 Removing and installing intake-air distributor - section on "Installing"
10. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2005
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Checking timing of camshafts Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Information
Note
Checking the timing is not possible for the M48/00 and M48/50 engines. Only an adjustment can be
made→ 150516 Adjusting timing for camshafts.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Adjusting the timings for the camshafts Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Adjusting the timings for the camshafts Page 3 of 7
Preliminary work
Preliminary work
Note
To remove the play from the timing chain for the setting process, the crankshaft must be positioned at least
45° in front of the TDC of cylinder 1 before turning!
1. Remove camshaft housing cover on both cylinder rows → 159121 Removing camshaft housing cover -
Chapter "Removing".
ATTENTION
Damage to engine by turning crankshaft against the rotation
direction of the engine (engine assembled)!
Note
The setting is always checked simultaneously on both cylinder rows. Once a cylinder row has been set, the
crankshaft must not be turned to set the other cylinder row!
The fastening screws on the sprocket wheels do not need to be replaced after they have been undone.
The screws on the sprocket wheels are tightened by hand during assembly and are then loosened by one or
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two turns. This play is necessary so that the camshafts can still be turned.
The setting is carried out with the standard chain tensioner that is installed.
2. Use socket wrench insert 9714 to turn crankshaft until cylinder 1 is in ignition TDC. Insert fixing pins
9595/1 into the relevant groove in the timing chain housing cover through the bore provided in the crankshaft
gearwheel -see figure- .
Note
If the cams on cylinder 1 are not positioned as shown, check whether
the crankshaft needs to be turned through another turn (360°)!
Cams of cylinder 1
Special tools
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Tools
The crankshaft is positioned in the TDC and is fixed using fixing pins 9595/1 once the above preliminary check
has been performed.
Note
The fastening screws on the sprocket wheels do not need to be replaced after they have been undone.
1. Undo all four fastening screws of the camshaft wheels (two camshaft adjusters) on both cylinder rows. For
this purpose, hold the hexagon of the camshaft wheel on the respective camshaft with the ring wrench and
release pan-head screw M12 1 by 2 revolutions
--To illustrate the process more clearly, the figure does not show the timing case lid-- .
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Note
Cylinder rows 1 - 4 and 5 - 8 are adjusted at the same time without
the camshaft being turned!
Hexagon on camshaft
Note
Cylinder rows 1 - 4 and 5 - 8 are adjusted at the same time without
the camshaft being turned!
3. Then adjust camshafts of the other cylinder row. For this purpose,
turn the hexagon with the open-ended wrench and fix it with
camshaft guide 9678. . Check whether the camshaft guide
alternately fits into the grooves on both cylinder rows of the
camshafts.
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4. Tighten all camshaft wheels (two camshaft adjusters) again with pan-head screw M12. For this purpose, hold
hexagon of the respective camshaft with ring wrench and tighten M12 pan-head screw. For tightening
torques, see → 150719 Removing and installing camshaft wheel - Chapter "Reworking".
5. Remove camshaft guide 9678 and fixing pins 9595/1.
Subsequent work
Reworking
1. Install camshaft housing cover on both cylinder rows → 159123 Installing camshaft housing cover - Chapter
"Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
2. Remove camshaft adjusters. For details, refer to → 158419 Removing and installing camshaft adjusters -
"Removing" chapter.
3. Remove camshaft timing gears. For details, see → 150719 Removing and installing camshaft timing gear -
chapter on "Removing".
Removing camshafts
Removing camshafts
Note
While removing, note the installation position and allocation of the camshafts and bearing caps on a sheet of
paper in such a way that they cannot be mixed up.
Protect camshafts, bearing caps and camshaft housing from dirt and layout the components on a clean
surface according to installation position.
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Position of camshafts
1. Unscrew fastening screws M6 x 16 of the inlet camshaft oil feed housing and pull it off to the front.
Note
While removing, note the installation position and allocation of the camshafts and bearing caps on a sheet of
paper in such a way that they cannot be mixed up.
Protect camshafts, bearing caps and camshaft housing from dirt and layout the components on a clean
surface according to installation position.
Note
When releasing the camshaft bearing caps, all the fastening screws must be released evenly half a turn at a
time in the reverse order to that illustrated so that the camshaft is not distorted!
2. Remove all the M6 x 35 fastening screws of the thrust bearing cap and bearing caps evenly half a turn at a
time in the reverse order to that illustrated -see figure- . Layout thrust bearing and bearing caps on a clean
surface according to installation position.
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
2. Remove camshaft adjusters. For details, refer to → 158419 Removing and installing camshaft adjusters -
"Removing" chapter.
3. Remove camshaft timing gears. For details, see → 150719 Removing and installing camshaft timing gear -
chapter on "Removing".
Removing camshafts
Removing camshafts
Note
While removing, note the installation position and allocation of the camshafts and bearing caps on a sheet of
paper in such a way that they cannot be mixed up.
Protect camshafts, bearing caps and camshaft housing from dirt and layout the components on a clean
surface according to installation position.
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Position of camshafts
1. Unscrew fastening screws (M6 x 16) of the inlet camshaft oil feed housing and pull it off to the front.
Note
While removing, note the installation position and allocation of the camshafts and bearing caps on a sheet of
paper in such a way that they cannot be mixed up.
Protect camshafts, bearing caps and camshaft housing from dirt and layout the components on a clean
surface according to installation position.
Note
When releasing the camshaft bearing caps, all the fastening screws must be released evenly half a turn at a
time in the reverse order to that illustrated so that the camshaft is not distorted!
Note
As of model year 2005, the first camshaft bearing cap has two
standard bores for securing the hydraulic valve (two M6 x 60 screws)
-1- . An additional oil strainer is fitted under the hydraulic valve.
2. Remove all M6 x 35 fastening screws for the thrust bearing caps and
bearing caps evenly half a turn at a time in the reverse order to that
shown -see Figure- . Lay out thrust bearing and bearing caps on a
clean surface according to installation position.
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3. Remove camshafts and lay out on a clean surface according to installation position.
as of MY 2005
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installing camshafts
Installing camshafts
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Installing camshafts Page 3 of 6
Note
Ensure the bearing caps are correctly positioned and allocated.
Turn the crankshaft to about 30° before TDC cylinder 1 so that the
valves and pistons are not damaged when the camshaft bearing caps
are being tightened!
Note
Place the camshafts in such a way that the cams are positioned as shown below!
Note
The camshafts of the turbocharged engine have a blue colour identification, the camshafts of the naturally
aspirated engine a white colour identification.
3. Place camshafts as shown in the -illustration- . When doing so, pay particular attention to the relative
position of the cams to each other.
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4. Place oiled bearing caps on camshaft bearings. The matching number of the bearing caps must correspond
to the camshaft housing. For each cylinder, the bearing caps are numbered consecutively from the front
(timing chain side) -B- . The designation of the bearing cap and matching number can be read from the
exhaust side -A- .
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5. Fit bearing cap. The tightening sequence must be strictly observed → Tightening torque: 7.5 ftlb.
-tightening sequence- .
6. Fit oil feed housing of inlet camshaft. To do this, slide the well-oiled oil feed housing over the plain
compression rings of the camshaft → Tightening torque: 7.5 ftlb. .
Subsequent work
1. Install camshaft adjusters. For details, refer to → 158419 Removing and installing camshaft adjusters -
"Installing" chapter.
2. Install camshaft timing gears. For details see → 150719 Removing and installing camshaft timing gear -
chapter on "installing".
3. Install camshaft housing cover → 159123 Removing and installing cover for camshaft housing - chapter on
"installing".
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installing camshafts
Installing camshafts
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Installing camshafts Page 3 of 6
Note
Ensure the bearing caps are correctly positioned and allocated.
Turn the crankshaft to about 30° before TDC cylinder 1 so that the
valves and pistons are not damaged when the camshaft bearing caps
are being tightened!
Note
Place the camshafts in such a way that the cams are positioned as shown below!
Note
The camshafts of the turbocharged engine have a blue colour identification, the camshafts of the naturally
aspirated engine a white colour identification.
3. Place camshafts as shown in -Illustration- . When doing so, pay particular attention to the way the cams are
positioned in relation to each other.
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4. Put oiled bearing caps onto the camshaft bearings. The matching number of the bearing caps must
correspond to the camshaft housing. For each cylinder, the bearing caps are numbered consecutively from
the front (timing chain side) -B- . The designation of the bearing cap and matching number can be read from
the exhaust side -A- .
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Note
As of model year 2005, the first camshaft bearing cap has two
standard bores for securing the hydraulic valve (two M6 x 60 screws)
-1- . An additional oil strainer is fitted under the hydraulic valve.
6. Fit oil feed housing of inlet camshaft. To do this, slide the well-oiled oil feed housing over the plain
compression rings of the camshaft → Tightening torque: 10 (7.5 ftlb.) Nm .
Subsequent work
1. Install camshaft adjusters. For details, refer to → 158419 Removing and installing camshaft adjusters -
"Installing" chapter.
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2. Install camshaft timing gears. For details see → 150719 Removing and installing camshaft timing gear -
chapter on "installing".
3. Install camshaft housing cover → 159123 Removing and installing cover for camshaft housing - chapter on
"installing".
as of MY 2005
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
Special tools
Tools
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ATTENTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine assembled)!
→ Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing
chain jumps over).
→ Proceed carefully while working as otherwise the engine can be damaged.
→ Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
→ After working on the camshaft wheels, the timing must be set.
→ Please observe the general warning notes and working regulations → 1001AW The most important working
regulations and warning notes
1. Using socket 9714, turn the crankshaft until cylinder 1 is located at ignition TDC.
Note
If the cams on cylinder 1 are not positioned as shown, check whether
the crankshaft still needs to be turned through another turn (360°)!
3. Insert locating pin 9595/1 through the bore provided in the crankshaft gearwheel and into the relevant
groove in the timing chain housing cover -see figure- .
5. Loosen timing chain and pull upper plastic guide away from both pins. If necessary, turn camshaft timing
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Note
The fastening screws of the sprockets must be replaced after
removal.
7. If necessary, use a rubber hammer to carefully loosen the camshaft timing gear from the back.
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ATTENTION
Engine damage due to small parts falling into the timing case (e.g. diamond washer)!
→ Do not let the diamond washer under the camshaft timing gear and camshaft adjuster fall into the timing
case.
Note
There is a diamond washer between the camshaft and camshaft timing gear and between the camshaft and
camshaft adjuster. This is to be replaced after the corresponding wheel has been removed. If the fastening
screw of the wheel is only loosened to adjust the timing (1 or 2 revolutions), the diamond washer does not
need to be replaced.
8. Use both hands, to carefully remove the camshaft timing gear from the chain.
ATTENTION
Engine damage due to small parts falling into the timing case (e.g.
diamond washer)!
→ Do not let the diamond washer under the camshaft timing gear and
camshaft adjuster fall into the timing case.
Note
If they have been removed, replace the diamond washer and M12 cheese head screw of the camshaft.
1. Replace the diamond washer and M12 cheese head screw located under the camshaft timing gear.
2. Lift the timing chain and carefully place the camshaft timing gear on the camshaft. To get sufficient play in
the timing chain, it may be necessary to turn the loosened camshaft adjuster back and forth. Place timing
chain on camshaft timing gear.
3. Position new M12 fastening screw on camshaft timing gear and screw in loosely (it must still be possible to
turn the camshaft timing gear).
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Subsequent work
2. Install camshaft housing cover. → 159123 Removing and installing cover for camshaft housing - chapter on
"installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Separate engine from transmission and suspend it on the assembly support using engine support 9676.
3. Drain off engine oil and dispose of it in accordance with the applicable national laws. For details and
tightening torques, see → 170117 Changing engine oil and oil filter - section on "Draining".
4. Remove cover for camshaft housing. → 159121 Removing cover for camshaft housing - section on
"Removing"
5. Loosen (do not remove) the three fastening screws on the water pump pulley.
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Drive belt
Information
Component overview
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Installation location
Component overview
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Note
The description only explains how to remove the chain case lid. The removal of other components is
described in the corresponding chapters.
1. Remove the belt tensioner. To do this, loosen the fastening screws -4 and 5- on the carrier and on the
underside of the shock absorber.
2. Remove the deflector wheel at cylinder row 1-4. To do this, lever off the lid and unscrew the fastening screw.
3. Remove water pump belt pulley.
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Note
To ensure that the used
fastening screw of the
crankshaft belt pulley is not
used again, mark it with a felt-
tip pen.
Cable duct
7. Disconnect coolant line to the generator.
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ATTENTION
Risk of engine leaks!
When dismantling the timing-case cover, the sealing bead
between the oil pan and crankcase can become damaged.
12. Remove oil pan. → 175021 Oil pan removed - chapter on "Removing".
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\153321_1.htm 5/19/2011
Installing chain case lid Page 2 of 13
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Component overview
Installation location
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Installing chain case lid Page 3 of 13
Component overview
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
Note
Acetone can be used to clean the sealing faces. Ventilate this for 5 minutes before applying more sealant.
1. Clean and degrease the sealing faces of the engine and housing lid.
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2. Attach the four seals -1, 2, 3 and 4- to the chain case lid.
Lid seals
3. Apply a bead of liquid sealant 000.043.300.39 Loctite 5970 (status 11/2005, for details of currently used
sealant, see Parts Catalogue) to the contact points of the camshaft housing/cylinder head, cylinder
head/crankcase and crankcase upper section/crankcase lower section. The bead of sealant should protrude
about 20 mm over the contact points. → Sealant application
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Sealant application
Note
In the case of the M48/50 (turbo) engine, sealant must also be applied to the metal seal in the chain
tensioner area.
Sealant application
4. Screw down all fastening screws by hand. At this stage, the screw heads should not be all the way down.
Note
The chain case lid must be aligned using a dial gauge or steel gauge.
The chain case lid must not project over the lower section of the crankcase.
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1 - M6 x 25 screw
2 - M6 x 50 screw
3 - M8 x 50 screw
5. Push the chain case lid upwards slightly and tighten the fastening screws -7, 8, 9 and 10- (about 1 - 2 Nm
(0.5 - 1.5 ftlb.) in such a way that the lid is slightly jammed. Then align the lid. → 153123 15 Installing chain
case lid - section on "Adjusting"
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Tightening sequence
ATTENTION
Danger of leaks!
If the chain case lid is not aligned properly, this component or
the oil pan may start to leak during operation.
→ The chain case lid must not project over the crankcase.
→ It cannot go under 0.1 mm (dimension A = 0.1 mm).
1. Insert the dial gauge into the universal gauge holder and position it in
such a way that the dial gauge has a preload of about 1 mm. Adjusting the preload
2. Set dial gauge scale to 0. To do this, place the dial gauge holder on a
completely flat surface (e.g. crankcase flange) and turn the dial
gauge scale until the pointer is at 0.
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project out.
4. Align the chain case lid by tapping lightly with a rubber hammer.
Note
See figure! → Tightening sequence
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Tightening sequence
Tightening sequence
Subsequent work
Subsequent work
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Fastening screws
4. Fit crankshaft pulley. Fastening screw tightening torque: 250 Nm (185 ftlb.) + 90° torque angle. → 137619
Removing and installing crankshaft belt pulley - section on "Installing"
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5. Install bracket for oil-water heat exchanger. → 176723 Installing bracket for oil-water heat exchanger
Deflection roller
7. Tighten coolant pump pulley. → 195019 Removing and installing
coolant pump pulley - section on "Installing"
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Belt tensioner
8. Install belt tensioner. Install holder with tensioning element. Tighten the top fastening screw → Tightening
torque: 33 (24 ftlb.) Nm . Tighten the bottom fastening screw → Tightening torque: 32 (24 ftlb.) Nm
→ 137319 Replacing belt tensioner.
9. Fit and tension the drive belt. → 137819 Removing and installing
drive belt [9PAAF1 9PAAJ1]→ 137819 Removing and installing
drive belt [9PAAE1 9PAAE7]
Drive belt
10. Install chain tensioner with new sealing ring. → 153619 Removing
and installing chain tensioner - section on "Installing"
11. Install oil dipstick. → 171719 Removing and installing guide for oil
dipstick - section on "Installing"
Chain tensioner
12. Check timing and adjust if necessary. → 150516 Setting the timing
13. Install cover for camshaft housing (valve cover). → 159123 Installing
cover for camshaft housing
Camshaft guide
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\153323_1.htm 5/19/2011
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
ATTENTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine assembled)!
→ Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing
chain jumps over).
→ Proceed carefully while working as otherwise the engine can be damaged.
→ Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
→ After working on the camshaft wheels, the timing must be set.
→ Please observe the general warning notes and working regulations → 1001AW The most important working
regulations and warning notes
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove cover for camshaft housing. → 159121 Removing cover for camshaft housing
Information
Component overview
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Note
If the timing chain has to be removed or replaced, check the guide and tensioning rails for wear and scoring and
replace them if necessary.
Note
The rolling direction of the timing chain must always be the same.
Note
If the timing chain is to be reused, the rolling direction of the timing
chain must be marked before it is removed.
3. Mark rolling direction of timing chain. Remove timing chain from all
sprockets, pulling it forwards.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\153521_0.htm 5/19/2011
Fitting timing chain Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Component overview
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ATTENTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine assembled)!
→ Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing
chain jumps over).
→ Proceed carefully while working as otherwise the engine can be damaged.
→ Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
→ After working on the camshaft wheels, the timing must be set.
→ Please observe the general warning notes and working regulations → 1001AW The most important working
regulations and warning notes
Note
The rolling direction of the timing chain must always be the same.
If the timing chain is to be reused, the rolling direction of the timing chain must be marked before it is
removed.
Note
If the timing chain has to be removed or replaced, check the guide and tensioning rails for wear and scoring and
replace them if necessary.
Camshaft timing gears and camshaft adjusters must be installed and it must be possible to turn them.
1. Place timing chain loosely on all sprockets. Ensure that the timing chain is in the correct position on the
guide rails.
2. Fit guide and tensioning rails. For details, see → Removing and installing guide and tensioning rails
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Subsequent work
Subsequent work
3. Install cover for camshaft housing. → 159123 Installing cylinder head cover
4. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\153523_0.htm 5/19/2011
Removing and installing chain tensioner Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Component overview
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ATTENTION
Risk of damage to timing drive mechanism!
Never twist the crankshaft against the direction of rotation.
Remove and install the chain tensioner only in overlapping TDC. (The chain tensioner is under the
least amount of pressure in this position).
Never twist the crankshaft when the chain tensioner is removed.
→ Forces from the valve drive can cause the timing chain to jump over or tilt.
Note
All spark plugs (except for those on cylinder 3) must be removed to ensure that the relevant dead centre can
be found more easily.
Note
An alternative method for determining the overlapping TDC is the "cylinder
pipe" (dead centre finder). This tool is part of the pressure-loss tester WE
1066, Workshop Installation Manual 3.1.4.
– Then twist the crankshaft through 360° in the direction of motion. The engine is now located in the
overlapping TDC of cylinder 1.
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Cable clip
3. Open cable clip -7- of the generator's electric cable and press the cable upwards.
Note
If the chain tensioner is removed, the aluminium sealing ring must be replaced.
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1. Screw chain tensioner with new sealing ring -arrow- down by hand and tighten. → Tightening torque: 44
ftlb.
Cable clips
4. Install spark plugs and covers.→ 287055 Replacing spark plugs
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove cover for camshaft housing → 159121 Removing and installing cover for camshaft housing - section
on "Removing".
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Note
The hydraulic valve for camshaft adjustment as of model year 2005 does not fit on the bearing cap and
camshaft housing of model years 2003 to 2004.
If an engine of model years 2003 to 2004 is to be converted to suit a new hydraulic valve with oil strainer, the
camshaft housing and all camshaft bearing caps must be replaced.
Note
The hydraulic valve for camshaft adjustment as of model year 2005 does not fit on the bearing cap and
camshaft housing of model years 2003 to 2004.
If an engine of model years 2003 to 2004 is to be converted to suit a new hydraulic valve with oil strainer, the
camshaft housing and all camshaft bearing caps must be replaced.
1. Replace sealing ring on hydraulic valve -see Figure- . Do not insert sealing ring twisted when fitting.
2. Coat sealing ring lightly with engine oil and insert hydraulic valve into cylinder head.
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Subsequent work
Subsequent work
1. Install cover for camshaft housing → 159123 Removing and installing cover for camshaft housing - section
on "Installing".
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove cover for camshaft housing → 159121 Removing and installing cover for camshaft housing - section
on "Removing".
Note
The hydraulic valve for camshaft adjustment as of model year 2005 does not fit on the bearing cap and
camshaft housing of model years 2003 to 2004.
If an engine of model years 2003 to 2004 is to be converted to suit a new hydraulic valve with oil strainer, the
camshaft housing and all camshaft bearing caps must be replaced.
2. Remove oil strainer with a small magnet. If the oil strainer cannot be removed through the housing, the
bearing cap must be removed.
3. The oil strainer is located in the camshaft housing under the first camshaft bearing cap.
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Note
The hydraulic valve for camshaft adjustment as of model year 2005 does not fit on the bearing cap and
camshaft housing of model years 2003 to 2004.
If an engine of model years 2003 to 2004 is to be converted to suit a new hydraulic valve with oil strainer, the
camshaft housing and all camshaft bearing caps must be replaced.
1. Insert the oil strainer into the camshaft housing under the first
camshaft bearing cap. You do not have to remove the camshaft
bearing cap to do this (Figure shows oil strainer without camshaft
bearing cap → Oil strainer partly inserted in camshaft housing ).
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housing
Subsequent work
Subsequent work
1. Install cover for camshaft housing → 159123 Removing and installing cover for camshaft housing - section
on "Installing".
as of MY 2005
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove cover for camshaft housing . → 159121 Removing cover for camshaft housing - section on
"Removing"
4. Mark rolling direction of timing chain. Remove timing chain from all chain sprockets, pulling it forwards.
→ 153521 Removing timing chain - section on "Removing"
Information
Component overview
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Component overview 1
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Component overview 2
1- Tensioning rail
2- Threaded pegs
3- Guide rails
4- Threaded pegs
5- Chain tensioner M24 x 1.5; replace sealing ring
6- Guide rail
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Note
If the timing chain has to be removed or replaced, check the guide and tensioning rails for wear and scoring and
replace them if necessary.
Note
The rolling direction of the timing chain must always be the same.
If the timing chain is to be reused, the rolling direction of the timing chain must be marked before it is
removed.
Note
If the timing chain is to be reused, the rolling direction of the timing chain must be marked before it is
removed.
1. Remove top guide rails -6- if this has not yet been done. Pull guide rail -3- and tensioning rail -1- off threaded
pegs. Ensure that the spring of the tensioning rail for the oil pump drive is in the correct position in relation to
the guide rail -3- .
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2. Remove guide rail -3- by loosening four fastening screws (M8 x 35).
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Guide rail
3. Remove plastic lid of oil pump drive -7- . To do this, unscrew two M5 x 20 screws -8- and remove plastic lid.
Remove guide rail -9- and tensioning rail -6- .
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2. Fit guide rail -3- . To do this, screw in four fastening screws (M8 x 35). → Tightening torque: 24 ftlb.
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Guide rail
3. Attach guide rail -3- and tensioning rail -1- to threaded pegs. Position the spring of the tensioning rail for oil
pump drive correctly on guide rail -3- . Fit top guide rails -6- when installing the timing chains.
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Subsequent work
Subsequent work
1. Install timing chain. → 153523 Installing timing chain - section on "Installing"
3. Set the timing. → 150516 Adjusting timing for camshafts - section on "Adjusting"
4. Install cover for camshaft housing . → 159123 Installing cover for camshaft housing - section on "Installing"
5. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\154719_0.htm 5/19/2011
Removing and installing hydro-tappets Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove camshafts . → 150521 Remove camshafts - Chapter "Removing"
Removing hydro-tappets
Removing hydro-tappets
Note
If the flat-base tappets are to be reused, they must be marked
according to installation position using a water-resistant felt-tip pen
and stored in such a way that they cannot be mixed up!
1. Pull the flat-base tappets out of the camshaft housing one after the
other and store them in such a way that they cannot be mixed up.
Pulling flat-base tappets out of the
camshaft housing
E - Intake side
A - Exhaust side
5 bis 8 - Cylinders
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Removing and installing hydro-tappets Page 3 of 3
Installing hydro-tappets
1. Grease flat-base tappets with engine oil and reinsert into the
camshaft housing.
Subsequent work
Subsequent work
1. Install camshafts . → 150523 Install camshafts - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\155919_0.htm 5/19/2011
Removing and installing intake valve Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove cylinder head. → 157021 Removing cylinder head
3. Take flat-base tappets out of the cylinder head and lay them on a clean surface, arranged according to
cylinders and valves. → 155955 21 Removing and installing flat-base tappets - chapter on "Removing" . Do
not interchange components.
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Removing and installing intake valve Page 3 of 8
Information
Component overview
In the Turbo, the exhaust valve is fitted with internal and external valve springs and adapted concave
washers (different to those shown in the figure below). The exhaust valve in the turbo engine has the same
dimensions as the exhaust valve in the naturally aspirated engine; because of the sodium filling it is lighter
however and when obtained as a spare part it features a coloured dot to distinguish it. For further details,
please see later chapter entitled "Valve dimensions".
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6 - Valve guide
7 - Intake positioning ring
8 - Intake valve
9 - Exhaust positioning ring
10 - Exhaust valve
Note
Secure the cylinder head on a level surface, which allows easy access to the valves from underneath.
The cylinder head fastening must not tip over when tools are used.
Note
The illustrations show part of the cylinder head installed.
1. The spark plugs must be removed and the valve lock screwed in
before the valves are removed → Screwing in tool . The valve lock
prevents the valves from being opened while being pressed down.
Alternatively, a rubber plate placed underneath helps if the cylinder
head surface is smooth -2- .
Screwing in tool
Locking valves
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2. Fit and adjust lever tool from the valve key assembly/disassembly tool for the Cayenne NR.54-1 set on
the cylinder head. When doing so, ensure that the middle pipe is positioned centrally over the spark-plug
recesses. The operating lever can be secured centrally or excentrically. The fastening screws in the camshaft
bearing caps in the front and rear bearing position are used to secure the tool brackets → Removing tool
setup for valve springs (figure shows fitted cylinder head). Use the white plastic pressure piece with the
magnetic insert to remove the valve keys. The assembly must be performed as shown → Removing tool
setup for valve springs .
3. Press the white plastic pressure piece with the magnetic insert against
the top concave washer to remove the valve keys. The concave
washer -2- and the valve keys -1- are attracted to the magnetic insert
and release the valve (loosen valve keys with a screwdriver if they are
stuck). Remove loose components (valve springs, top concave
washer and valve keys). Repeat procedure as often as necessary for
the affected valves (reposition tool accordingly).
Locking valves
Note
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Removing and installing intake valve Page 6 of 8
Intake valves come in different sizes to exhaust valves. It is impossible to mix them up. Intake valves are
identical in the naturally aspirated and turbo engines.
Exhaust valves in the turbo engine weigh less than exhaust valves in the naturally aspirated engine. They are
marked with a green dot. Do not interchange them.
The valves can be grinded using commercially available valve grinding paste.
2. Oil the valve stem of a new valve and insert it into the valve guide from the combustion chamber. Push the
valve in until it is seated securely in the valve seat of the cylinder head.
3. Grind in the valve using the commercially available valve grinding tool
(with rubber suction cup) by means of rotary movements. To do this,
hold the valve grinder between the palms of both hands and press
against the valve seat with rotating movements → Grinding the valve
seat .
ATTENTION
Valve grinding paste residues can cause mechanical damage!
4. Carry out the grinding operation for each valve that is replaced. Check
for leaks using some fuel and installed spark plugs. The fuel must not
escape through the valve seat. Carefully remove valve grinding paste.
Locking valves
7. Fit valve springs, concave washer and valve keys. To do this, place valve springs (there are two in the
exhaust valve in the turbo engine) on the bottom concave washer. Place top concave washer in position. Pull
off the ring of the assembly tool -2- from the retaining springs -3- before inserting the valve keys. Position
valve keys with the thin side facing upwards -1- .
8. Insert valve keys into the assembly tool with the thin side facing upwards -1- . Ensure that the valve keys fit
symmetrically and are inserted as far as they will go in the assembly tool. The retaining springs are free -2- .
9. Secure the valve keys by pushing up the ring → Valve keys in assembly tool . Check that the valve keys are
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10. Insert valve key assembly tool in tool setup and position in front of the
valve stem. → Valve key assembly
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Subsequent work
Subsequent work
1. Fit flat-based tappets. Do not interchange components. → 155955 23 Removing and reinstalling flat-base
tappet - chapter on "Installing"
Information
Valve dimensions
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\156019_0.htm 5/19/2011
Removing and installing exhaust valve Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove cylinder head. → 157021 Removing cylinder head
3. Take flat-base tappets out of the cylinder head and lay them on a clean surface, arranged according to
cylinders and valves. → 155955 21 Removing and installing flat-base tappets - chapter on "Removing" . Do
not interchange components.
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Information
Component overview
In the Turbo, the exhaust valve is fitted with internal and external valve springs and adapted concave
washers (different to those shown in the figure below). The exhaust valve in the turbo engine has the same
dimensions as the exhaust valve in the naturally aspirated engine; because of the sodium filling it is lighter
however and when obtained as a spare part it features a coloured dot to distinguish it. For further details,
please see later chapter entitled "Valve dimensions".
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6 - Valve guide
7 - Intake positioning ring
8 - Intake valve
9 - Exhaust positioning ring
10 - Exhaust valve
Note
Secure the cylinder head on a level surface, which allows easy access to the valves from underneath.
The cylinder head fastening must not tip over when tools are used.
Note
The illustrations show part of the cylinder head installed.
1. The spark plugs must be removed and the valve lock screwed in
before the valves are removed → Screwing in tool . The valve lock
prevents the valves from being opened while being pressed down.
Alternatively, a rubber plate placed underneath helps if the cylinder
head surface is smooth -2- .
Screwing in tool
Locking valves
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Removing and installing exhaust valve Page 5 of 8
2. Fit and adjust lever tool from the valve key assembly/disassembly tool for the Cayenne NR.54-1 set on
the cylinder head. When doing so, ensure that the middle pipe is positioned centrally over the spark-plug
recesses. The operating lever can be secured centrally or excentrically. The fastening screws in the camshaft
bearing caps in the front and rear bearing position are used to secure the tool brackets → Removing tool
setup for valve springs (figure shows fitted cylinder head). Use the white plastic pressure piece with the
magnetic insert to remove the valve keys. The assembly must be performed as shown → Removing tool
setup for valve springs .
3. Press the white plastic pressure piece with the magnetic insert against
the top concave washer to remove the valve keys. The concave
washer -2- and the valve keys -1- are attracted to the magnetic insert
and release the valve (loosen valve keys with a screwdriver if they are
stuck). Remove loose components (valve springs, top concave
washer and valve keys). Repeat procedure as often as necessary for
the affected valves (reposition tool accordingly).
Locking valves
Note
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Removing and installing exhaust valve Page 6 of 8
Intake valves come in different sizes to exhaust valves. It is impossible to mix them up. Intake valves are
identical in the naturally aspirated and turbo engines.
Exhaust valves in the turbo engine weigh less than exhaust valves in the naturally aspirated engine. They are
marked with a green dot. Do not interchange them.
The valves can be grinded using commercially available valve grinding paste.
2. Oil the valve stem of a new valve and insert it into the valve guide from the combustion chamber. Push the
valve in until it is seated securely in the valve seat of the cylinder head.
3. Grind in the valve using the commercially available valve grinding tool
(with rubber suction cup) by means of rotary movements. To do this,
hold the valve grinder between the palms of both hands and press
against the valve seat with rotating movements → Grinding the valve
seat .
ATTENTION
Valve grinding paste residues can cause mechanical damage!
4. Carry out the grinding operation for each valve that is replaced. Check
for leaks using some fuel and installed spark plugs. The fuel must not
escape through the valve seat. Carefully remove valve grinding paste.
Locking valves
7. Fit valve springs, concave washer and valve keys. To do this, place valve springs (there are two in the
exhaust valve in the turbo engine) on the bottom concave washer. Place top concave washer in position. Pull
off the ring of the assembly tool -2- from the retaining springs -3- before inserting the valve keys. Position
valve keys with the thin side facing upwards -1- .
8. Insert valve keys into the assembly tool with the thin side facing upwards -1- . Ensure that the valve keys fit
symmetrically and are inserted as far as they will go in the assembly tool. The retaining springs are free -2- .
9. Secure the valve keys by pushing up the ring → Valve keys in assembly tool . Check that the valve keys are
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10. Insert valve key assembly tool in tool setup and position in front of the
valve stem. → Valve key assembly
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Subsequent work
Subsequent work
1. Fit flat-based tappets. Do not interchange components. → 155955 23 Removing and reinstalling flat-base
tappet - chapter on "Installing"
Information
Valve dimensions
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing valve-stem seal Page 2 of 10
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
Preliminary work
Note
The cylinder head can remain fitted while this work is carried out.
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
3. Take flat-base tappets out of the cylinder head and lay them on a clean surface, arranged according to
cylinders and valves. → 155955 21 Removing and installing flat-base tappets - section on "Removing" . Do
not interchange components.
Information
Component overview
In the Turbo, the exhaust valve is fitted with internal and external valve springs and adapted concave
washers (different to those shown in the figure below). The exhaust valve in the turbo engine has the
same dimensions as the exhaust valve in the naturally aspirated engine; because of the sodium filling it is
lighter however and when obtained as a spare part it features a coloured dot to distinguish it. For further
details, please see later chapter entitled "Valve dimensions".
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Note
When required, all valve-stem seals on both cylinder rows must be replaced.
Note
Before switching to another cylinder, the cylinder must be positioned at the bottom dead centre and supplied
with compressed air (see above).
Note
Position the pistons of the relevant cylinder at the bottom dead centre.
1. Set piston for the corresponding cylinder to bottom dead centre. To do this, guide the timing chain carefully
when turning the crankshaft.
2. Screw in compressed-air hose from the valve key assembly/disassembly tool for the Cayenne NR.54-1
tool set in the relevant spark plug bore so that it is tightly sealed. Apply compressed air constantly to cylinder
(at least 6 bar overpressure). This builds up the pressure in the cylinder so that the valve does not fall
into the cylinder while the work is being carried out. Replace all four valve-stem seals for a cylinder and
refit valve keys. Only then fit compressed-air hose on the next cylinder and apply compressed air constantly.
3. Fit and adjust lever tool from the valve key assembly/disassembly
tool for the Cayenne NR.54-1 set on the cylinder head. When doing
so, ensure that the middle pipe is positioned centrally over the spark-
plug recesses. The operating lever can be secured centrally or
excentrically. The fastening screws in the camshaft bearing caps in
the front and rear bearing position are used to secure the tool
brackets → Removing valve keys (figure shows fitted cylinder head).
Use the white plastic pressure piece with the magnetic insert to
remove the valve keys. The assembly must be performed as shown
→ Removing valve keys .
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Closed puller
7. Remove valve-stem seal by activating the negative (slide) hammer.
-arrow- . Repeat procedure for valves on pressurised cylinder
(reposition tool accordingly).
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Note
Position the pistons of the relevant cylinder at the bottom dead centre.
Note
Before switching to another cylinder, the cylinder must be positioned at the bottom dead centre and supplied
with compressed air (see above).
Note
When required, all valve-stem seals on both cylinder rows must be replaced.
Note
Protective caps must be ordered as separate spare parts. They are reusable. They are used to protect the valve-
stem seal so that it is not damaged at the valve stem end.
1. Prepare valve-stem seal -1- , protective cap -3- and assembly driver
9606/1 -2- .
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10. Replace all four valve-stem seals for a cylinder and refit valve keys.
Only then fit compressed-air hose on the next cylinder and apply
compressed air constantly.
Subsequent work
Subsequent work
1. Fit flat-based tappets. → 155955 23 Removing and installing flat-base tappets - section on "Installing" . Do
not interchange components.
3. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
Information
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Removing and installing valve-stem seal Page 10 of 10
Valve dimensions
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\156319_0.htm 5/19/2011
Removing cylinder head Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Note
If more comprehensive work, e.g. replacement of the entire cylinder head, is intended, the exhaust manifolds
must also be removed. → 261019 Removing and installing exhaust manifold - Chapter "Removing" [9PAAE1
9PAAE7]→ 261019 Removing and installing exhaust manifold - Chapter "Removing" [9PAAF1 9PAAJ1]
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove cover for camshaft housing . → 159121 Removing cover for camshaft housing - section on
"Removing"
3. Remove intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - section on
"Removing"
Information
Component overview
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Component overview
1- Cap
2- Cylinder head
3- Straight pin
4- Pan-head screw M12 x 1.5 x 140
5- Cap
6- Spark plug
7- Cap
8- Cylinder-head gasket
9- Vent connection
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2. Remove oil separator vent line from cylinder head. To do this, unscrew the fastening screws -3 and upper 4-
.
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3. Disconnect vent line for cylinder heads. To do this, press the ribbed surfaces of the buttons and pull off the
plugs.
Note
In the case of the turbocharged engine (M48/50), only the upper fastening screws of the turbocharger need
to be undone.
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
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C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\157021_0.htm 5/19/2011
Installing cylinder head Page 2 of 9
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Component overview
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Component overview
1- Cap
2- Cylinder head
3- Straight pin
4- Pan-head screw M12 x 1.5 x 140
5- Cap
6- Spark plug
7- Cap
8- Cylinder-head gasket
9- Vent connection
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ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
Note
All sealing surfaces must be clean and free of grease!
1. Place cylinder head gasket correctly, i.e. according to the specifications, onto the straight pins of the engine
crank housing. This must be done in such a way that the "Top" marking can be read -figure- .
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2. Fit cylinder head. Insert M12 x 1.5 x 140 cylinder head screws
(screws can be used again).
Setting torque
→ torque angle: 90 °
Note
In the case of the turbocharged engine (M48/50), screw down the
upper fastening screws of the turbocharger.
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7. Mount oil separator vent line onto cylinder head with new sealing ring
-2- . To do this, position and tighten the fastening screws
-3 and upper 4- . → Tightening torque: 7.5 ftlb.
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8. Fasten guide rail of timing chain -3- . To do this, tighten the fastening screws -4- . → Initial tightening: 11
ftlb. → Final tightening: 90 °
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Subsequent work
Subsequent work
1. Install camshaft housing. → 150323 Install camshaft housing – section on "Installing"
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3. Install intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - section on "Installing"
4. Install cover for camshaft housing . → 159123 Installing cover for camshaft housing - section on "Installing"
5. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Note
Only replace studs if they are damaged or their reliability can no longer be assured!
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Replacing attachment for exhaust manifold (stud) Page 3 of 5
Exhaust manifold
1. Screw two M8 nuts onto the stud and counter with two open-ended
wrenches.
Note
Before inserting the new stud, the internal thread in the cylinder head must be checked for damage!
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Replacing attachment for exhaust manifold (stud) Page 4 of 5
Unscrewing stud
3. Screw in new stud hand-tight, then screw two nuts onto the new stud
as before and counter.
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Replacing attachment for exhaust manifold (stud) Page 5 of 5
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing camshaft adjusters Page 2 of 9
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
Special tools
Tools
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Note
The timing is always set simultaneously on both cylinder banks. Once a cylinder bank has been set, the
crankshaft must not be turned to set the other cylinder bank!
The fastening screws of the chain sprockets must be replaced after removal.
The diamond washers of the chain sprockets must be replaced after removal.
The screws on the sprocket wheels are tightened by hand during assembly and are then loosened by one or
two turns. This play is necessary so that the camshafts can still be turned.
The cylinder bank is set with the standard chain tensioner that is installed.
ATTENTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine assembled)!
→ Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing
chain jumps over).
→ Proceed carefully while working as otherwise the engine can be damaged.
→ Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
→ After working on the camshaft wheels, the timing must be set.
→ Please observe the general warning notes and working regulations → 1001AW The most important working
regulations and warning notes
1. Using socket 9714, turn the crankshaft until cylinder 1 is located at ignition TDC.
Note
If the cams on cylinder 1 are not positioned as shown, check whether the crankshaft needs to be turned
through another turn (360°)!
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2. Make sure that the cams for the 1st cylinder and 5th cylinder are positioned as shown (cylinder 1 at ignition
TDC) -see figure- and → View shows position of cams on cylinder 5 .
5. Loosen the timing chain and pull the upper plastic guide off the two pins. If necessary, use a ring wrench to
turn the camshaft timing gear back and forth to provide more clearance for the timing chain between the
wheels → Upper plastic guide for timing chain .
Note
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6. Only loosen the fastening screw of the camshaft timing gear (one or two turns). To do this, use a ring wrench
to counter at the a/f 32 hexagon on the camshaft adjuster and on the camshaft timing gear of the
corresponding camshaft. Unscrew only the M12 cheese head bolt of the camshaft adjuster using a T60
socket -figure shows procedure without timing-case cover for a better view- .
7. Loosen the camshaft adjuster from the back with a rubber hammer.
ATTENTION
Engine damage due to small parts falling into the timing case (e.g. diamond washer)!
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→ Do not let the diamond washer under the camshaft timing gear and
camshaft adjuster fall into the timing case.
Note
There is a diamond washer between the camshaft and camshaft
timing gear or camshaft adjuster. This must be replaced after the
corresponding wheel has been removed. If the fastening screw of the
wheel is only loosened in order to adjust the timing (1 or 2
revolutions), the diamond washer and fastening screw do not need to
be replaced.
Take camshaft adjuster out of the
8. With both hands, carefully take the camshaft adjuster out of the chain
chain.
ATTENTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine assembled)!
→ Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing
chain jumps over).
→ Proceed carefully while working as otherwise the engine can be damaged.
→ Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
→ After working on the camshaft wheels, the timing must be set.
→ Please observe the general warning notes and working regulations → 1001AW The most important working
regulations and warning notes
Note
If the diamond washer and pan-head screw M12 are removed, replace the camshaft.
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1. Replace the diamond washer and M12 cheese head bolt which are located underneath the camshaft
adjuster.
ATTENTION
Engine damage due to small parts falling into the timing case (e.g.
diamond washer)!
→ Do not let the diamond washer under the camshaft timing gear and
camshaft adjuster fall into the timing case.
5. Install chain tensioner -arrow- . For chain tensioner tightening torque, see → 153619 Removing and
installing chain tensioner - chapter on "Installing".
Subsequent work
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2. Install camshaft housing cover. → 159123 Removing and installing cover for camshaft housing - chapter on
"installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\158419_0.htm 5/19/2011
Replacing lid seal for camshaft housing (valve lid seal) Page 2 of 2
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Information
1. In order to change the camshaft housing cover seal, the camshaft housing cover must be removed and
installed.→ 159121 Removing camshaft housing cover → 159123 Installing camshaft housing cover
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\159055_0.htm 5/19/2011
Removing cover for camshaft housing Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
Preliminary work
1. Remove engine cover → 108319 Removing and installing engine cover - Chapter "Removing".
2. Remove secondary air pump with console → 266519 Removing and installing secondary air pump - Chapter
"Removing".
3. Remove ignition coils (ignition rod module). Refer to→ 282055 Replacing ignition coils
Special tools
Note
It is best to use a tool that has an head height of less than 50 mm -A-
(see special tools) to loosen and tighten the rear fastening screw of
the cylinder head cover close to the plenum panel.
Tool height
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Information
Component overview
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1 - Design cover
2 - Ball socket
3 - Cover holder
4 - BM8 x 45 screw
5 - Hexagon-head bolt M6 x 40
6 - Engine support bracket
7 - M6 x 30 oval-head screw
8 - Camshaft housing cover on cylinder 1 - 4
9 - Camshaft housing cover seal, inner and outer
10 - Seal for NVS camshaft housing
11 - Cap
12 - Ignition coil (ignition rod module)
13 - Screw with internal thread
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14 - Grommet
15 - Sleeve
16 - Countersunk screw, M5 x 16
Note
The cover for the camshaft housing is removed and installed in the same way on cylinder bank 5 - 8 and
cylinder bank 1 - 4!
Note
Plastic clips can be damaged once the wiring harness holder has been undone and must be checked to
ensure they can be used again!
3. Remove wiring harness holders by pulling carefully on the holders. Lay wiring harness aside.
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ATTENTION
Risk of damage to the position sensor on the camshaft's trigger wheel!
The trigger wheel can be damaged when the cover of the camshaft housing is moved.
Ignition faulty.
Engine damage.
Note
If the camshaft housing lid is not removed carefully, it can cause the trigger wheel on the position sensor at
the rear on the camshaft to be bent out of shape!
Note
It is best to use a tool that has an head height of less than 50 mm -A-
(see special tools) to loosen and tighten the rear fastening screw of
the cylinder head cover close to the plenum panel.
5. Unscrew screws -1 to 19- ( -16 and 19- were mounted on the torque
support bracket) and lift the camshaft housing lid carefully at the back
to avoid damaging the trigger wheel of the reference mark sender on
the camshaft (this is located in the vicinity of screws 1 and 7). Then
lift it off completely.
Tool height
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6. Turn the camshaft housing lid over and remove inner and outer seal
for camshaft housing. Clean sealing faces on the camshaft housing
lid and cylinder head.
Note
Always replace seals.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Installing cover for camshaft housing Page 2 of 10
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Installing cover for camshaft housing Page 3 of 10
Special tools
Note
It is best to use a tool that has an head height of less than 50 mm -A-
(see special tools) to loosen and tighten the rear fastening screw of
the cylinder head cover close to the plenum panel.
Tool height
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Information
Component overview
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1 - Design cover
2 - Ball socket
3 - Cover holder
4 - BM8 x 45 screw
5 - Hexagon-head bolt M6 x 40
6 - Engine support bracket
7 - M6 x 30 oval-head screw
8 - Camshaft housing cover on cylinder 1 - 4
9 - Camshaft housing cover seal, inner and outer
10 - Seal for NVS camshaft housing
11 - Cap
12 - Ignition coil (ignition rod module)
13 - Screw with internal thread
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14 - Grommet
15 - Sleeve
16 - Countersunk screw, M5 x 16
ATTENTION
Risk of damage to the position sensor on the camshaft's trigger wheel!
The trigger wheel can be damaged when the cover of the camshaft housing is moved.
Ignition faulty.
Engine damage.
Note
The cover for the camshaft housing is removed and installed in the same way on cylinder bank 5 - 8 and
cylinder bank 1 - 4!
Note
Always replace inner and outer seal for camshaft housing!
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Note
If the camshaft housing cover is not fitted carefully, it can cause the
trigger wheel on the position sensor at the rear on the camshaft to be
bent out of shape!
3. Position the camshaft housing lid carefully; do not bend the trigger
wheel of the position sensor on the camshaft when doing so.
Note
It is best to use a tool that has an addendum of less than 50 mm -A- (see special tool) to tighten the rear
fastening screw on the cylinder head cover close to the plenum panel.
6. Position all fastening screws and tighten them in accordance with the correct tightening sequence →
Tightening torque: 13 (9.5 ftlb.) Nm -see figures for both cylinder rows- . Screws
-18 and 19 cylinder rows 1 to 4- are inserted later with the torque support bracket.
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Tool height
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Wiring harness
8. Fit wiring harness holder with new plastic clips. To do this, simply
press on the wiring harness holder.
10. Attach plug connection for the positive crankcase ventilation to the
flange on the camshaft housing lid.
Cable plug
12. Connect ignition coil. To do this, push on the connector until it locks
with an audible click.
Ignition coil
13. Install bracket for torque support. Tighten the M8 x 45 Torx screws at the top screw points. → Tightening
torque: 17 ftlb. Tighten the M6 x 40 screws at the bottom screw fastening points (middle of valve cover). →
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Subsequent work
Subsequent work
1. Install ignition coils (ignition rod modules). Refer to→ 282055 Replacing ignition coils
2. Install secondary air pump with console. → 266519 Removing and installing secondary air pump - Chapter
"Installing".
3. Install engine cover . → 108319 Removing and installing engine cover - Chapter "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Engine oil and oil filter change Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Engine oil and oil filter change Page 3 of 6
Overview
Note
Engine oil should not be extracted as particles of dirt may remain in the oil pan.
WARNING
Hot oil!
Danger of scalding!
2. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
3. Loosen the 2 oil drain plugs and collect engine oil in a disposal
container. Dispose of waste oil in accordance with legal
requirements.
5. Fill in engine oil of the stipulated viscosity and quality. The oil change quantity is → filling capacity: 8.25
litre .
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Note
Engine oil should not be extracted as particles of dirt may remain in the oil pan.
2. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
WARNING
Hot oil!
Danger of scalding!
3. Loosen the 2 oil drain plugs and collect engine oil in a disposal
container. Dispose of waste oil in accordance with legal
requirements.
4. Clean oil drain plug and screw in with new aluminium sealing ring. →
Tightening torque: 37 ftlb.
6. Remove the oil filter housing vertically downwards. Drain the remaining oil into a disposal container.
7. Remove the filter element. Remove the filter downwards and dispose of in accordance with legal
requirements.
Note
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Engine oil and oil filter change Page 5 of 6
The oil filter housing contains a cutout via which the O-ring can be
removed.
Note
Lightly oil the O-ring when installing the oil filter housing.
10. Install the oil filter housing and tighten using special tool oil filter
spanner 9204. Lightly oil the O-ring when doing this. → Tightening Cleaning the oil-filter housing
torque: 19 ftlb.
12. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
1. Pull out oil dipstick and wipe it off with a clean, lint-free cloth. Insert oil dipstick again fully, pull it out again,
and read off the oil level. Correct engine-oil level if necessary.
The oil level on the oil dipstick must never be below the MIN mark or above the MAX mark.
Note
After changing the oil, the oil level must be checked using the dipstick.
Max. mark
Min. mark
Range from min up to max. mark: no more oil must be added.
Range below Min. mark: refill engine oil up to Max. mark.
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Engine oil and oil filter change Page 6 of 6
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\170117_1.htm 5/19/2011
Checking oil pressure Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Special tools
Oil-pressure gauge
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Checking oil pressure Page 3 of 6
Equipment Manual,
Chapter 3.1.4"
WARNING
Engine oil is toxic.
Danger of poisoning!
WARNING
Danger of scalding from hot oil!
→ Engine oil and components of the oil circuit can become very hot!
→ Allow engine and components to cool down.
→ Avoid contact with the skin and eyes.
→ Wear suitable protective clothing.
WARNING
Oil is combustible!
Risk of fire due to oil and hot components (exhaust manifold, etc.)
→ Do not pour engine oil over very hot components (e.g. turbocharger).
→ Never place cloths soaked with oil on hot engine components.
→ In case of fire, use CO2 or dry powder fire extinguishers.
Note
The oil pressure may be too low for a number of reasons:
Oil is diluted.
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Incorrect oil has been used. Use only oil that has been approved by Porsche for the measurement.
Note
The oil pressure switch is located on the oil-filter console to the right (in the direction of travel) under the
generator.
Overview
1. Remove front engine guard. → 108019 Removing and installing engine guard - chapter on "Removing"
Note
When the oil pressure switch is unscrewed, approx. 0.3 litres of engine oil escapes.
3. Loosen the oil pressure switch and unscrew it. Collect the emerging oil and dispose of it in accordance with
the applicable national laws.
4. Screw in test adapter 4 with sealing ring in the oil-filter console and tighten by hand.
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Note
The oil temperature must range between 80°C and 100°C when
performing the measurement.
6. Start the engine and move off at the required test speed. Read off
the oil pressure on the pressure gauge when doing so. Connecting pressure gauge
Note
When the pressure gauge is unscrewed, approx. 0.3 l of engine oil escapes.
7. Remove pressure gauge with test hose. Collect the emerging engine oil and dispose of it in accordance with
the applicable national laws.
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9. Push electric connector onto oil pressure switch. The connector must
engage audibly.
10. Install front engine guard. → 108019 Removing and installing engine
guard - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing oil-pressure sender Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
WARNING
Engine oil is toxic.
Danger of poisoning!
WARNING
Danger of scalding from hot oil!
→ Engine oil and components of the oil circuit can become very hot!
→ Allow engine and components to cool down.
→ Avoid contact with the skin and eyes.
→ Wear suitable protective clothing.
WARNING
Oil is combustible!
Risk of fire due to oil and hot components (exhaust manifold, etc.)
→ Do not pour engine oil over very hot components (e.g. turbocharger).
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Removing and installing oil-pressure sender Page 3 of 4
Note
The oil pressure may be too low for a number of reasons:
Oil is diluted.
Incorrect oil has been used. Only use oil that has been approved by Porsche for the measurement.
Note
The oil pressure switch is located on the oil-filter console to the right under the generator.
Overview
1. Remove front underside panel. → 108019 Removing and installing engine guard - chapter on "Removing"
2. Pull off connector on oil pressure sensor. To do this, press on the button.
Note
When the oil pressure switch is unscrewed, approx. 0.3 litres of engine oil escapes.
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Removing and installing oil-pressure sender Page 4 of 4
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\170419_1.htm 5/19/2011
Removing and installing oil level sensor Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
WARNING
Engine oil is toxic.
Danger of poisoning!
WARNING
Danger of scalding from hot oil!
→ Engine oil and components of the oil circuit can become very hot!
→ Allow engine and components to cool down.
→ Avoid contact with the skin and eyes.
→ Wear suitable protective clothing.
WARNING
Oil is combustible!
Risk of fire due to oil and hot components (exhaust manifold, etc.)
→ Do not pour engine oil over very hot components (e.g. turbocharger).
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Removing and installing oil level sensor Page 3 of 5
Overview
1. Remove underbody panel. → 108019 Removing and installing engine guard - chapter on "Removing"
Note
If the oil is to be used again, it must be collected in a clean container.
2. Undo the 2 oil drain plugs and collect engine oil in a container.
Dispose of waste oil in accordance with legal requirements.
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Removing and installing oil level sensor Page 4 of 5
Loosening fastening screws for oil Electric connector on oil level sensor
level sensor
5. Loosen the 3 fastening screws and pull the oil level sensor out of the oil pan.
1. Install the new oil level sensor with a new seal. Tighten the 3
fastening screws. → Tightening torque: 7.5 ftlb.
4. Install underbody panels. → 108019 Removing and installing engine guard - chapter on "Installing"
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Removing and installing oil level sensor Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\171119_0.htm 5/19/2011
Removing and installing guide for oil dipstick Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove throttle body cover. Pull the cover up and off. → 108319
Removing and installing engine cover - chapter on "Removing"
2. Remove Y-shaped pipe. → 243519 Removing and installing air box
for throttle housing (Y-shaped pipe) - chapter on
"Removing" [9PAAF1 9PAAJ1]→ 243519 Removing and installing air
box for throttle housing (Y-shaped pipe) - chapter on
"Removing" [9PAAE1 9PAAE7]
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Removing and installing guide for oil dipstick Page 3 of 5
Overview
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Removing and installing guide for oil dipstick Page 4 of 5
4. Replace O-ring.
6. Tighten the 2 fastening screws. First position the two screws. Then tighten the upper fastening screw. →
Tightening torque: 7.5 ftlb. and then the lower fastening screw → Tightening torque: 7.5 ftlb. .
Subsequent work
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Removing and installing guide for oil dipstick Page 5 of 5
Subsequent work
1. Reinstall the Y pipe. → 243519 Removing and installing air box for throttle housing (Y-shaped pipe) - chapter
on "Installing" [9PAAF1 9PAAJ1]→ 243519 Removing and installing air box for throttle housing (Y-shaped
pipe) - chapter on "Installing" [9PAAE1 9PAAE7]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\171719_0.htm 5/19/2011
Removing and installing oil pump Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove oil pan. → 175021 Removing oil pan - chapter on "Removing"
Information
Component overview
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Removing and installing oil pump Page 3 of 8
Overview
Note
The oil pump must not be disassembled and reassembled!
When carrying out work on the oil circuit, it must be ensured that no dirt gets into the engine!
Note
The oil pump can be replaced while installed.
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Removing and installing oil pump Page 4 of 8
Oil pump
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Removing and installing oil pump Page 5 of 8
7. Push the tensioning rail for the oil pump drive aside with a finger. At the same time, raise the oil pump
slightly and tilt forwards.
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Removing and installing oil pump Page 6 of 8
8. Take the oil pump drive chain off the oil pump sprocket and remove the oil pump.
9. Unscrew the oil suction snorkel from the oil pump.
Note
In order to make it easier to install the oil suction pumps in the Cayenne Turbo (M48/50), it should be
ensured that the driving slits on the chain sprocket are as horizontal as possible.
1. Position the oil pump slanting forwards on the lower section of the
crankcase. At the same time, put the drive chain over the chain
sprocket.
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Removing and installing oil pump Page 7 of 8
Oil pump
ATTENTION
Risk of damage!
The tensioning rail can become wedged in!
4. Mount the plastic cover of the chain sprocket. Tighten the two
fastening screws. → Tightening torque: 4.2 ftlb.
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Removing and installing oil pump Page 8 of 8
6. Attach the four fastening screws for the oil suction tube to the lower
part of the crankshaft housing. → Tightening torque: 9.5 ftlb.
Subsequent work
Subsequent work
1. Check that the timing chain has not jumped over. To do this, turn the engine by two turns at the crankshaft.
Make sure you can turn the engine without any mechanical resistance. Otherwise, set the timing. → 150516
Setting the timing
2. Reinsert the cleaned oil pan. → 175023 Installing oil pan (includes sealing) - chapter on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\172019_0.htm 5/19/2011
Disassembling and assembling oil pressure control valve Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Overview
Note
The description only applies when installed.
file://E:\POSES\data\rl\2\9PA\172637_0.htm 5/19/2011
Disassembling and assembling oil pressure control valve Page 3 of 4
Component overview
Note
When unscrewing the oil pressure control valve, ensure that the
screw plug is under spring pressure.
3. Remove the four components of the oil pressure control valve → Valve body . Always replace sealing ring.
Note
Ensure that the installation opening of the oil pump housing is clean!
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Disassembling and assembling oil pressure control valve Page 4 of 4
Note
Screw in the screw plug by Valve body Valve body
hand against the spring pressure.
2. Prevent the valve body from falling and screw in the spring, new sealing ring and screw plug.
4. Install oil pan. → 175023 Oil pan installed (includes sealing) - chapter
on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\172637_0.htm 5/19/2011
Removing and installing oil filter Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
WARNING
Engine oil is toxic.
Danger of poisoning!
WARNING
Danger of scalding from hot oil!
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Removing and installing oil filter Page 3 of 3
→ Engine oil and components of the oil circuit can become very hot!
→ Allow engine and components to cool down.
→ Avoid contact with the skin and eyes.
→ Wear suitable protective clothing.
1. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
2. Loosen oil filter with special tool oil filter spanner 9204 and unscrew
it.
Oil filter
Note
Do not remove the O-ring with a sharp object.
The oil filter housing contains a cutout via which the O-ring can be
removed.
5. Clean the oil filter housing and replace the O-ring seal. Clean the oil
filter housing thoroughly inside and outside and replace the O-ring.
Carefully lever off the O-ring. The oil filter housing must not be
damaged during this procedure.
Oil-filter housing sealing ring
6. Install the filter element.
Note
Lightly oil the O-ring when installing the oil filter housing.
7. Install the oil filter housing and tighten using special tool oil filter spanner 9204. → Tightening torque: 19
ftlb. Lightly oil the O-ring when doing this.
8. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
9. Fill engine oil, start engine and check oil level. → 170117 Engine oil and oil filter change - chapter on
"Checking"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\173019_0.htm 5/19/2011
Removing and installing oil-water heat exchanger Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Information
Component overview
Note
The illustrations apply to the Cayenne Turbo (M48/50).
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Removing and installing oil-water heat exchanger Page 3 of 8
Overview of V8 engine
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Removing and installing oil-water heat exchanger Page 4 of 8
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Removing and installing oil-water heat exchanger Page 5 of 8
Overview of bracket
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Removing and installing oil-water heat exchanger Page 6 of 8
Note
The illustrations apply to the Cayenne Turbo (M48/50).
If a fault in the oil-water heat exchanger has caused oil and coolant to mix, the oil circuit should be checked
to see if there is coolant in the engine or, if necessary, be cleaned.
If oil has entered the coolant circuit, this is to be cleaned after repair . → 190129 Cooling system cleaned
(after oil/coolant mixing)
2. Release the 4 fastening screws on the heat exchanger and pull the
heat exchanger down and off. During this process, both engine oil
and coolant will leak out. Collect leaking liquids and dispose of in
accordance with legal requirements.
Öl/Wasser-Wärmetauscher einbauen
Note
The illustrations apply to the Cayenne Turbo (M48/50).
If a fault in the oil-water heat exchanger has caused oil and coolant to mix, the oil circuit should be checked
to see if there is coolant in the engine or, if necessary, be cleaned.
If oil has entered the coolant circuit, this is to be cleaned after repair . → 190129 Cooling system cleaned
(after oil/coolant mixing)
1. Replace the 2 sealing rings of the oil circuit. When doing this, pay attention to the lugs on the sealing ring.
Subsequently, push the oil-water heat exchanger from underneath against the bracket and tighten the 4
fastening screws. → Tightening torque: 7.5 ftlb.
2. Push the coolant hoses onto the connecting flanges and secure with the spring-band clamps.
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Removing and installing oil-water heat exchanger Page 7 of 8
Subsequent work
2. Fit the sheetmetal brace under the radiator. To do this, tighten the
four fastening screws. → Tightening torque: 17 ftlb.
Engine guard
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Removing and installing oil-water heat exchanger Page 8 of 8
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\174019_0.htm 5/19/2011
Removing oil pan Page 2 of 10
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\175021_0.htm 5/19/2011
Removing oil pan Page 3 of 10
Preliminary work
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Removing oil pan Page 4 of 10
Preliminary work
Engine guard
2. Drain coolant circuit. → 193817 Draining and filling coolant (includes
bleeding) - chapter on "Draining"
Draining coolant
Note
If the oil does not yet have to be replaced, collect it in a clean
container and use again.
3. Drain oil. To do this, loosen and unscrew the two oil drain plugs.
4. Clean oil drain plugs and screw in with a new sealing ring. →
Tightening torque: 37 ftlb.
Note
If the transmission is still connected, the 2 lower transmission screws must be removed first.
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Removing oil pan Page 5 of 10
9. Remove oil dipstick. → 171719 Removing and installing guide for oil Transmission screws
dipstick - chapter on "Removing"
V8 engines
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Removing oil pan Page 6 of 10
Pulley on crankshaft
12. Remove oil-filter console. To do this, unscrew the 4 fastening screws
(3x M 8 x 70 and 1x M 8 x 45). Pull oil-filter console off forwards.
Further details: → 176721 Removing bracket for oil-water heat
exchanger - chapter on "Removing"
Special tools
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Removing oil pan Page 7 of 10
Tools
Information
Component overview
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Removing oil pan Page 8 of 10
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Note
The description only applies when installed.
If the oil pan is removed when the transmission is disconnected, the oil pan must be aligned with the aid of a
dial gauge (see chapter Aligning oil pan with a dial gauge).
To remove the oil pan, it is not necessary to remove the timing case cover. If the timing case cover is
removed while carrying out work later, the oil pan must be removed with it.
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Removing oil pan Page 10 of 10
Note
In the case of the Cayenne
Turbo, the oil suction pump of
the turbocharger must also be
removed. To do this, release
screws -1 to 6- one after the
other.
2. Subsequently, tighten the nut on the puller until the sleeve can be
pulled out.
Note
If the oil pan is stuck, loosen it by gently tapping with a plastic
hammer. Nut on puller
5. Remove oil pan. Remove the oil pan from the crankshaft. At the same time, swing downwards and forwards.
6. Clean sealing faces. Brush off rest of the sealant with a plastic brush and then degrease the sealing face.
Note
The black plastic feeder must not be taken out of the oil pan.
If this component has been damaged or removed, the entire oil pan must be removed.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\175021_0.htm 5/19/2011
Installing oil pan (includes sealing) Page 2 of 10
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\175023_0.htm 5/19/2011
Installing oil pan (includes sealing) Page 3 of 10
Special tools
file://E:\POSES\data\rl\2\9PA\175023_0.htm 5/19/2011
Installing oil pan (includes sealing) Page 4 of 10
Tools
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Installing oil pan (includes sealing) Page 5 of 10
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
ATTENTION
Risk of damage and leaks!
If the oil pan is not correctly aligned, it can become leaky during
operation.
2. Apply liquid sealant. Apply the sealing agent Loctite 5970 (000 043 300 39, status 12/05) using the hand-
held cartridge. The contour of the bead of sealant must comply with the figure shown below. The bead of
sealant should be approx. 1.5 mm high. The oil duct in the timing-case cover -A- must remain clear and must
not be obstructed with silicone.
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Installing oil pan (includes sealing) Page 6 of 10
Note
If the transmission is removed, the oil pan must be aligned with the aid of a dial gauge. → 175023 Oil pan
installed (includes sealing) - chapter on "Fitting"
3. Place the oil pan on the crankcase and push evenly against the transmission cover.
4. Screw in a fastening screw on each corner of the oil pan and tighten them by hand.
5. Then screw in all fastening screws by hand. While doing this, push the oil pan towards the transmission.
6. Tighten the 29 fastening screws beginning at the transmission flange and proceed forwards. → Tightening
torque: 10 (7.5 ftlb.) Nm
7. Screw down the timing case cover. Tighten the 5 fastening screws M 6 x 25 with an E10 wrench. →
Tightening torque: 10 (7.5 ftlb.) Nm
Note
In the Cayenne Turbo (M48/50), the oil suction pump of the
turbocharger must also be fitted. Further details: → 218023
23 Installing oil suction pump for turbocharger - chapter on "Installing"
8. Install oil transfer flange. Replace and grease the O-rings of the
flange. Then place the connection piece on the assembly driver
9691 in such a way that the slightly thicker end points forwards.
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Installing oil pan (includes sealing) Page 7 of 10
Socket
Aligning the oil pan with a dial gauge
ATTENTION
Risk of damage and leaks!
If the oil pan is not correctly aligned, it can become leaky during operation.
→ Align the oil pan extremely accurately in compliance with this description.
→ Ensure that there is no dirt between the 2 components.
Place the oil pan on the crankcase and position a fastening screw on each corner.
Note
The following work steps are only necessary if the transmission is
disconnected at the time the oil pan is being installed.
1. Insert the dial gauge into the universal dial gauge holder and position
it such that the dial gauge has a preload of about 1 mm.
Dial gauge
2. Set dial gauge scale to 0. To do this, place the dial gauge holder on a
completely flat surface (e.g. crankcase flange) and turn the dial
gauge scale until the pointer is on 0.
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ATTENTION
Oil leakage!
If the oil pan is not correctly aligned, it can become leaky.
→ The oil pan lid must not project over the crankcase.
→ The oil pan must not go under 0.1 mm.
→ Oil pan must be installed in a straight position.
3. Measure offset. In order to do this, push with the holder starting from
the crankcase flange towards the oil pan flange (the foot of the dial Measuring offset
gauge holder is located on the other component like the dial gauge
probe) and measure the offset. The oil pan must not be set back any
more than 0.1 mm. A projection is not permissible.
5. After the oil pan has been aligned, tighten the 4 fastening screws. →
Tightening torque: 7.5 ftlb. The check the position of the oil pan
again with the dial gauge.
6. Tightening the remaining fastening screws. → Tightening torque:
7.5 ftlb.
Fastening screws
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Subsequent work
Subsequent work
Length-compensating element
3. Install crankshaft pulley. → 137619 Removing and installing
crankshaft pulley - chapter on "Installing"
Crankshaft pulley
4. Install engine carrier.→ 103019 Removing and installing engine carrier - chapter on "Installing"
5. Install the suspension subframe (front-axle carrier). → 400619 Removing and installing front-axle carrier -
chapter on "Installing" [9PAAJ1]→ 400619 Removing and installing front-axle carrier - chapter on "Installing"
[9PAAE1 9PAAE7 9PAAF1]
7. Install oil dipstick. → 171719 Removing and installing guide for oil dipstick - chapter on "Installing"
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10. Bleed and fill the cooling circuit. → 193817 Draining and filling
coolant (includes bleeding) - chapter on "Filling"
11. Carry out a check. After a test drive, check to ensure that the oil pan
is not leaking. Then check the oil level.
Engine carrier
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
4. Clean oil drain plug and screw in with new aluminium sealing ring. →
Tightening torque: 37 ftlb.
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Information
Component overview
Note
The illustrations apply to the Cayenne Turbo (M48/50).
Overview of V8 engine
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Overview of bracket
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Note
The following step must only be performed for the M48/50 engine.
1. Undo both oil return lines from the turbochargers to the oil filter
bracket. Pull the connections slightly out of the bracket.
ATTENTION
Danger of injury!
When pulling the bracket off, even greater amounts of engine oil
can leak out.
If the bracket is stuck, it can loosen abruptly. If this happens,
your fingers could be injured.
4. Pull off the bracket from the engine in a forward direction. If the bracket is stuck very firmly, lever it off very
carefully using a suitable implement.
as of MY 2003
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Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Component overview
Note
The illustrations apply to the Cayenne Turbo (M48/50).
Overview of V8 engine
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Overview of bracket
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2. Replace the O-rings on the oil transfer flange. To do this, lever off the O-rings with a non-abrasive implement
(plastic wedge) and replace them with new ones.
ATTENTION
Danger from oil-water heat exchanger!
If the compensating element is not screwed in, the bracket can
be braced and will break during operation as a result.
4. Apply a thin coat of engine oil to the two transfer flanges and position the bracket on the engine. Then push
the bracket hard against the engine until the fastening screws can be put into place.
5. The sleeve -1- is screwed in. Position the two fastening screws
-arrows- and tighten until hand-tight.
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Note
The following step must only be performed for the M48/50 (V8 Turbo)
engine.
9. Fit oil return lines for turbochargers. Insert the lines into the
connections and align them. Then screw in the union nuts by hand
and tighten them. → Tightening torque: 26 ftlb.
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Subsequent work
Subsequent work
1. Fasten lock mount. → 503809 Detaching and fastening lock mount (service position) - chapter on "fastening"
2. Fit the support plate under the radiator. To do this, tighten the 4
fastening screws. → Tightening torque: 17 ftlb.
Engine guard
5. Fill and bleed the cooling system. → 193817 Draining and filling coolant (includes bleeding) - chapter on
"Filling"
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Cooling system
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Checking cooling system Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Tools
A- Cooling system leak tester (pump) see Workshop Equipment Manual, Chapter 3 "WE1069"
B- Hose extension FZ 100
C- K22 cap adapter (for sports cars)
D- K60 cap adapter included (in scope of delivery Filling device 9696 )
ATTENTION
Danger of poisoning!
Coolant additives and cleaning liquids are toxic.
DANGER
The vehicle fans can continue running or start up automatically.
Injuries which can lead to the loss of body parts.
→
The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or the
belt drive. → Disconnect fuse carrier [9PAAE1 9PAAE7 9PAAF1]→ Disconnect fuse carrier [9PAAD1
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ATTENTION
Risk of damaging the cooling system!
→ Do not relieve the system pressure of the cooling system and then run the engine.
→ Relieving the system pressure and subsequently starting the engine can cause severe damage to
components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling
system to cool down before starting the engine again.
Note
The coolant filled in at the factory is intended to suffice for the entire service life. As long as the coolant is not
contaminated by foreign bodies or other fluids it need not be changed.
Different coolant additives must not be mixed and doing so may damage the cooling system. Only use
original Porsche coolant additives.
The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50 : 50
(coolant additive : water). This mixing ratio provides optimum corrosion and antifreeze protection.
Coolant additives, coolants and cleaning agents must be disposed of according to the respective, applicable
national laws.
Seals in the cooling system must be replaced by new ones following disassembly.
Maintenance cover
ATTENTION
Danger of scalding with hot coolant!
→ Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause scalding.
→ The cooling system must be depressurised before being opened.
→ Allow engine to cool down.
2. Carefully open the cap on the coolant reservoir. Unscrew the cap in an anti-clockwise direction.
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Note
The following table specifies how much coolant must be replaced by
pure antifreeze in order to adjust the freezing point to -37 °C.
Note
The following diagram shows the scale used by Leitenberger.
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Refractometer
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Pipette
Note
The following table specifies how much coolant must be replaced by
pure antifreeze in order to adjust the freezing point to -37 °C.
1. Check the cooling system for leaks. To do this, apply a test pressure
of approx. 1.5 bar using the cooling system test device and check
hose connections for leakage. The pressure must not drop.
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3. Screw on the cap of the coolant reservoir again until it locks with an
audible click.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
ATTENTION
Danger of poisoning!
Coolant additives and cleaning liquids are toxic.
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DANGER
The vehicle fans can continue running or start up automatically.
Injuries which can lead to the loss of body parts.
→ The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or the
belt drive. → Disconnect fuse carrier [9PAAE1 9PAAE7 9PAAF1]→ Disconnect fuse carrier [9PAAD1
9PAAD7 9PAAJ1] or battery → Work instructions after disconnecting the battery
ATTENTION
Risk of damaging the cooling system!
→ Do not relieve the system pressure of the cooling system and then run the engine.
→ Relieving the system pressure and subsequently starting the engine can cause severe damage to
components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling
system to cool down before starting the engine again.
Note
The coolant filled in at the factory is intended to suffice for the entire service life. As long as the coolant is not
contaminated by foreign bodies or other fluids it need not be changed.
Different coolant additives must not be mixed and doing so may damage the cooling system. Only use
original Porsche coolant additives.
The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50 : 50
(coolant additive : water). This mixing ratio provides optimum corrosion and antifreeze protection.
Coolant additives, coolants and cleaning agents must be disposed of according to the respective, applicable
national laws.
Seals in the cooling system must be replaced by new ones following disassembly.
Note
The cleaning work steps must be repeated until no more oil rises to
the surface in the coolant reservoir.
2. Fill the cooling circuit with the cleaning agent mixture. To do this, proceed with the cooling system
analogously to filling the coolant. → 193817 Draining and filling in coolant (includes bleeding) - chapter on
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"Filling in"
4. After the vehicle has been bled and the coolant temperature is > 80 °C, let the stationary vehicle run at
medium engine speed for at least 15 minutes.
ATTENTION
Danger of scalding with hot coolant!
→ Never open the cooling system when it is hot. Emerging coolant may
be very hot and can cause scalding.
→ The cooling system must be depressurised before being opened.
→ Allow engine to cool down.
8. Use hot water to rinse out any oil which has adhered inside the
coolant reservoir.
9. Close the cooling system and fill the coolant circuit with water only
and then bleed the cooling system according to regulations.
→ 193817 Draining and filling coolant (includes bleeding)
11. After the vehicle has been bled and the coolant temperature is > 80 °
C, let the stationary vehicle run at medium engine speed for at least Coolant drain plug
15 minutes.
ATTENTION
Danger of scalding with hot coolant!
→ Never open the cooling system when it is hot. Emerging coolant may
be very hot and can cause scalding.
→ The cooling system must be depressurised before being opened.
→ Allow engine to cool down.
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14. Drain cooling system. → 193817 Draining and filling coolant (includes bleeding)
15. Close the cooling system and bleed with the approved antifreeze mixture according to regulations.
→ 193817 Draining and filling coolant (includes bleeding)
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
The small fan on the left is for the air conditioning - the big fan on the right is for engine cooling
Note
The big fan is for the engine cooling, the small fan is for the air conditioning
The sheetmetal clips on the fans are for balancing the fans and must not be pulled off.
1. Remove the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) -
chapter on "Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 21 Removing and installing
cooling fan housing (radiator frame) - chapter on "Removing" [9PAAJ1]
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View shows the removal process Fastening screws for securing fan to
air conditioner
1. Push fan cable with control module from underneath through the
radiator frame.
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1. Push fan from the bottom into the frame and tighten the 3 fastening
screws to 4 Nm (3 ftlb.).
Subsequent work
Subsequent work
The small fan on the left is for the air conditioning - the big fan on the right is for engine cooling
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Note
The big fan is for the engine cooling, the small fan is for the air conditioning
The sheetmetal clips on the fans are for balancing the fans and must not be pulled off.
1. Install the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) - chapter
on "Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and installing cooling
fan housing (radiator frame) - chapter on "Installing" [9PAAJ1]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Removing the front engine compartment cover. → 700219 Removing and reinstalling front cover (engine
compartment) - chapter on "Removing"
2. Remove Y-shaped pipes. → 243519 Removing and installing air box for throttle housing (Y-shaped pipe) -
chapter on "Removing" [9PAAF1]→ 243519 Removing and installing air box for throttle housing (Y-shaped
pipe) - chapter on "Removing" [9PAAD1 9PAAD7]→ 243519 Removing and installing air box for throttle
housing (Y-shaped pipe) - chapter on "Removing" [9PAAE1 9PAAE7]
DANGER
The vehicle fans can continue running or start up automatically.
Injuries which can lead to the loss of body parts.
→ The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or the
belt drive. → Disconnect fuse carrier [9PAAE1 9PAAE7 9PAAF1]→ Disconnect fuse carrier [9PAAD1
9PAAD7] or battery → Work instructions after disconnecting the battery
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Note
The repair instructions differ slightly in the illustrations for the V6. The work steps are essentially identical.
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View of the catch springs when the Upper fastening screws for radiator
radiator has been removed motor
If the radiator frame is stuck, it can be released carefully by means of a
crowbar.
2. Check whether the installation is correct. To do this, check whether the catch springs on the left and right
have engaged properly and that the four fastening projections on the underside have engaged in the plastic
clamps.
3. Tighten the two upper fastening screws of the radiator module on the
lock carrier.
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Subsequent work
Subsequent work
1. Install Y-shaped pipes. → 243519 Removing and installing air box for throttle housing (Y-shaped pipe) -
chapter on "Installing" [9PAAF1]→ 243519 Removing and installing air box for throttle housing (Y-shaped
pipe) - chapter on "Installing" [9PAAD1 9PAAD7]→ 243519 Removing and installing air box for throttle
housing (Y-shaped pipe) - chapter on "Installing" [9PAAE1 9PAAE7]
2. Install front engine cover. → 700219 Removing and reinstalling front cover (engine compartment) - chapter
on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Special tools
Special tools 1
-- Flexible screwdriver a/f 7 (for loosening or tightening screw hose clamps) Flexible screwdriver a/f 7
A- NR.73-1
-- Antifreeze protection testing device (for checking the antifreeze content in the cooling system. The design
B- can deviate from that shown in the picture.)
-- Spring band clamp pliers (for opening and closing spring band clamps) Assembly tools for spring band
C- clamps NR.72
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-1- - Canister (canister with lifting tube, capacity approx. 30 l, with volume scale)
-2- - Hose extension
-3- - Adapter K 22 (included in the scope of delivery of radiator vacuum filling device)
-4- - Venturi nozzle (included in the scope of delivery of radiator vacuum filling device)
-5- - Adapter K 60 (included in the scope of delivery of radiator vacuum filling device)
-6- - Pressure gauge (included in the scope of delivery of radiator vacuum filling device)
Information
Note
Pay attention to the special features in the corresponding chapter for vehicles with auxiliary heater.
→ 193817 Draining and filling coolant (includes bleeding) - chapter on "Bleeding"
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Draining coolant
Draining coolant
ATTENTION
Danger of poisoning!
Coolant additives and cleaning liquids are toxic.
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ATTENTION
Danger of scalding with hot coolant!
→ Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause scalding.
→ The cooling system must be depressurised before being opened.
→ Allow engine to cool down.
DANGER
The vehicle fans can continue running or start up automatically.
Injuries which can lead to the loss of body parts.
→ The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or the
belt drive. → Disconnect fuse carrier [9PAAE1 9PAAE7 9PAAF1]→ Disconnect fuse carrier [9PAAD1
9PAAD7 9PAAJ1] or battery → Work instructions after disconnecting the battery
ATTENTION
Risk of damaging the cooling system!
→ Do not relieve the system pressure of the cooling system and then run the engine.
→ Relieving the system pressure and subsequently starting the engine can cause severe damage to
components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling
system to cool down before starting the engine again.
Note
The coolant filled in at the factory is intended to suffice for the entire service life. As long as the coolant is not
contaminated by foreign bodies or other fluids it need not be changed.
Different coolant additives must not be mixed and doing so may damage the cooling system. Only use
original Porsche coolant additives.
The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50 : 50
(coolant additive : water). This mixing ratio provides optimum corrosion and antifreeze protection.
Coolant additives, coolants and cleaning agents must be disposed of according to the respective, applicable
national laws.
Seals in the cooling system must be replaced by new ones following disassembly.
2. Carefully open the cap on the coolant reservoir. Unscrew the cap in an anti-clockwise direction.
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Engine guard
4. Remove engine guard. → 108019 Removing and installing engine guard - chapter on "Removing"
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hose on the radiator, and drain the coolant into a container and dispose of it according to the applicable
national laws if no longer required.
8. Fit a new drain plug on the radiator and tighten it. If removed, fasten coolant hose.
9. Install the support plate under the radiator. Tighten the four fastening
screws. → Tightening torque: 17 ftlb.
3. Connect the vacuum pressure gauge of the bleeder tool to the flexible extension. When doing so, ensure
that both shut-off valves are closed (positioned at 90° to flow direction).
Note
The coolant amount provided must be approx. 2 litres more than the amount which has to be filled. →
Technical data for M48/00 engine (Cayenne S) [9PAAE1 9PAAE7]→ Technical data for M48/00 engine
(Cayenne S) [9PAAD1 9PAAD7 9PAAF1 9PAAJ1], → Technical data for M48/50 engine (Cayenne
Turbo) [9PAAF1 9PAAJ1]→ Technical data for M48/50 engine (Cayenne Turbo) [9PAAD1 9PAAD7 9PAAE1
9PAAE7], → Technical data for BFD engine (Cayenne ) [9PAAD1 9PAAD7]→ Technical data for BFD
engine (Cayenne ) [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
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6. Push the filler hose -5- of the vacuum pressure gauge onto the canister connection. Lay the return line -6-
from the Venturi nozzle to a second container (bucket).
Note
A hissing sound after connecting the compressed air supply is usual.
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9. Close the left shut-off valve (V1) on the vacuum pressure gauge and
allow a vacuum to build up in the cooling system.
Note
If no vacuum is generated (the pointer does not move to the green
area), there is a leak in the cooling system.
When the pressure gauge pointer is in the green area of the display
scale, a sufficient vacuum has been built up.
After both shutoff valves on the vacuum pressure gauge have been
closed and the compressed air supply has been disconnected, the When there is sufficient vacuum, close
vacuum must not drop. If the vacuum drops within approx. 30 the right shut-off valve (V2)
seconds, there is a leak in the coolant circuit.
10. When there is a sufficient vacuum in the cooling system (indicator is in the green area), close the right shut-
off valve (V2) and then disconnect the compressed air supply.
11. Re-open the left shut-off valve (V1) on the vacuum pressure gauge. The cooling system is then filled.
12. When there is no trace of vacuum present or the coolant is no longer drawn from the canister, open the right
shut-off valve (V2).
13. Then remove the complete filling tool (including the cap K 60).
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14. If necessary, fill the coolant reservoir with coolant to the maximum marking.
Note
If necessary, the system can be checked for leaks. → 190101
Checking cooling system - chapter on "Checking"
Reservoir cap
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Note
Do not activate the 2/3 directional-control valve with the Porsche System Tester above 1500 rpm.
Activate the 2/3 directional-control valve with the Porsche System Tester below 1500 rpm.
3. Operate engine for 5 minutes with changing engine speeds. When doing this, run the engine for 10 seconds
in idle and then for 10 seconds at 4,000 rpm. In the speed transition from higher engine speeds (1500 to
4000 rpm) to idle (approx. 600), the directional-control valve should be activated with the Porsche System
Tester below 1500 rpm. Note that the 2/3 directional-control valve is not activated with the Porsche System
Tester above 1500 rpm.
Maintenance cover
6. Carefully open the cap on the coolant reservoir. Unscrew the cap in
an anti-clockwise direction.
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Reservoir cap
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
3. Detach the torque support. To do this, unscrew the fastening screw on the torque support bracket and pull it
out.
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5. Undo torque support bracket fastening screw from the body. One
fastening screw is loosened through the headlight opening. The
second screw is accessible from the top.
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6. Remove body bracket. When doing this, unclip the electric cable (2 x).
7. Loosen the secondary air pump from cylinder row 1-4. → 266519 Removing and installing secondary air
pump - chapter on "Removing"
Fastening screw
9. Pull coolant reservoir towards engine and take out of the holder.
Coolant reservoir
1. Insert coolant reservoir into the holder and push in the direction of the wing.
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Coolant hoses
10. Connect electric plug to reservoir.
Subsequent work
Subsequent work
1. Install the engine compartment cover at the right and rear. → 700219 Removing and reinstalling front cover
(engine compartment) - chapter on "Installing"
2. Install right headlight. → 941519 Removing and installing main headlight - chapter on "Installing"
3. Fill and bleed the cooling system. → 193817 Draining and filling coolant (includes bleeding) - chapter on
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"Filling"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
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1. Insert the additional coolant pump in the screw-type hose clamp and
screw in the fastening screw hand-tight. Install the coolant hoses
-2 and 3- , position the spring-band clamps and then connect the
electric connector -1- . Clip coolant lines into holder and fasten
sheetmetal holder of coolant line by mounting the fastening screw on
the body. → Tightening torque: 7.5 ftlb.
Subsequent work
Subsequent work
Note
If necessary, the system can be checked for leaks. → 190101 Checking cooling system
1. Fill and bleed the cooling system. → 193817 Draining and filling coolant (includes bleeding) - chapter on
"Filling"
2. Install front left wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"Installing".
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Radiator frame
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Information
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1- Coolant pump
2- Seal for coolant pump (replace seal)
3- 2 dowel sleeves (do not remove)
4- 8 M6x25 fastening screws (tightening torque 10 Nm (7.5 ftlb.))
5- Support for cable duct (fit with the two upper fastening screws)
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Note
To ease removal, spray the pulley from the rear side with an anti-
corrosion agent.
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Belt tensioner
ATTENTION
Risk of damaging pulley!
7. Remove the eight fastening screws on the coolant pump and remove
the pump. If the pump is stuck, loosen it by gently tapping with a
plastic hammer.
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ATTENTION
Risk of damaging pulley!
→ The pulleys of the engine accessories are made of plastic. Do not use damaged pulleys.
→ The pulley is sensitive to impacts.
→ Do not prise off the pulley with a screwdriver.
3. Fit the pulley on the coolant pump. Screw in the three fastening
screws by hand.
4. Mount drive belt -as shown in the following- . To do this, turn the
belt tensioner clockwise and thread the drive belt around all the
pulleys. Then carefully relieve the tensioning roller . → 137819
Removing and installing drive belt - chapter on "Installing" [9PAAF1
9PAAJ1]→ 137819 Removing and installing drive belt - chapter on
"Installing" [9PAAE1 9PAAE7]
Mount the fastening screws for the
coolant pump
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Subsequent work
Subsequent work
1. Install the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) - chapter
on "Installing" [9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and installing cooling fan housing
(radiator frame) - chapter on "Installing" [9PAAJ1]
2. Fill and bleed the cooling system according to instructions. → 193817 Draining and filling coolant (includes
bleeding) - chapter on "Filling"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Drain cooling system. → 193817 Draining and filling coolant (includes bleeding)
2. Remove intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Removing"
Information
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Install location
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Component overview
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Removing thermostat
6. Remove the coolant return line on the thermostat housing. To do this, loosen the fastening screw and pull off
the line.
7. Disconnect vent line for cylinder heads. To do this, press the ribbed surfaces of the buttons and pull off the
plugs.
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Fastening screw for coolant return line Spring band clamp for coolant return
to thermostat housing to generator
9. Undo the thermostat housing cover. The sequence shown must be observed when doing so.
10. Lift the housing cover. Remove the thermostat using assembly aid 9627.
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Note
All seals between opened sealing surfaces must be replaced.
1. Insert thermostat in the cover and turn it until the two sheetmetal
edges are lying to the left and right of the holder.
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4. Tighten the three rear fastening screws (M6 x 16) on the heater
pipes. → Tightening torque: 7.5 ftlb.
7. Push coolant line onto generator and fit the spring-band clamp.
8. Push the holder onto the timing case cover below the cable duct and tighten the fastening screw. →
Tightening torque: 7.5 ftlb.
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Subsequent work
Subsequent work
1. Install intake distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on "Installing"
2. Fill coolant system and check for leaks. → 193817 Draining and filling coolant (includes bleeding) - chapter
on "Filling"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Disconnect battery. → 90 Work instructions after disconnecting the battery
2. Drain cooling system. → 193817 Draining and topping up with coolant (includes bleeding) - chapter on
"Draining"
3. Remove lock mount. → 503819 Removing and installing lock mount - chapter on "Removing"
4. Remove the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) -
chapter on "Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 21 Removing and installing
cooling fan housing (radiator frame) - chapter on "Removing" [9PAAJ1]
Information
Component overview
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Overview of radiator
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Removing radiator
Do not open the air conditioner if at all possible when removing the - radiator module. Do not bend the lines
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Note
The retaining clips should be mounted again immediately so that they
are not confused.
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-A- and push it to the left out of the support -B- . Hang the radiator carefully downwards.
6. Lift both locks for the ATF cooler and air-conditioning condenser with
a screwdriver -1- and push down -arrow- .
Note
Fix the remaining radiators in the installation position using tie wraps.
7. Lift up the radiator and take it out of the vehicle by moving it up and
to the right. When doing this, watch out for the connection lines of the
air-conditioning system on the left side.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
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C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39,
C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Component overview
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Overview of radiator
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Installing radiator
Note
The retaining clips should be mounted again immediately so that they are not confused.
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Do not open the air conditioner if at all possible when removing the - radiator module. Do not bend the lines
1. Insert the radiator from above on the right between the ATF cooler
and the air-conditioning condenser.
5. Screw in both fastening screws -C- for securing condenser to the coolant radiator (left direction of travel). →
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Fastening screws for securing Fastening screw for servo oil coolant
condenser to coolant radiator line
Tightening torque: 6 ftlb.
6. Push on the cooler vent line onto the right radiator side and fit the
spring-band clamp.
Subsequent work
Subsequent work
1. Install the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) - chapter
on "Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and installing cooling
fan housing (radiator frame) - chapter on "Installing" [9PAAJ1]
2. Install lock mount. → 503819 Removing and installing lock mount - chapter on "Installing"
3. Fill and bleed the cooling system. → 193817 Draining and filling in coolant (includes bleeding) - chapter on
"Filling in"
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4. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Draining coolant
Information
Component overview
Installation Location:
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Component overview
1 - Distributor pipe
2 - Coolant temperature sensor (when removing, collect emerging coolant, when installing, replace sealing ring)
3 - Sealing ring (replace when installing)
4 - 3 screw plugs, M16x1 (when removing, collect emerging coolant, when installing, replace sealing ring)
5 - 10 hexagon-head bolts M6x25
6 - 2 seals for distributor pipe (when installing, clean sealing faces and replace seal)
7 - 4 sealing rings (when installing, grease with Klüber Syntheso GLEP 1
8 - Lower cooling water tube
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ATTENTION
Danger of poisoning!
Coolant additives and cleaning liquids are toxic.
ATTENTION
Danger of scalding with hot coolant!
→ Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause scalding.
→ The cooling system must be depressurised before being opened.
→ Allow engine to cool down.
Note
Even when the coolant has been completely drained, coolant
emerges from the open bore on the coolant temperature sensor!
2. Unscrew the coolant temperature sensor using a ring wrench (a/f 22)
-see picture- . Absorb emerging coolant.
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Subsequent work
Subsequent work
1. Install intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Installing"
2. Fill up completely with coolant and bleed system. → 193817 Draining and filling coolant (includes bleeding) -
chapter on "Filling".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Required tools
The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions
are noted).
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Lifting platform
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Tools overview
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Tools overview
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Preliminary work
Preliminary work
If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing
air-conditioning compressor removed during removal of the engine as the replacement engine is
delivered with the new compressor mounted. → 873419 Removing and installing air-conditioning
compressor - chapter on "Removing"
Fix steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering
wheel in centre position with steering wheel holder)! If this is not done, the airbag contact unit will have to
be put in centre position after installation of the steering gear! → 945019 Removing and reinstalling
steering-column switch
Position the vehicle at the take-up points provided on a lifting platform. → Lifting the vehicle [9PAAE1
9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1]
Put on the protective covers.
Produce the OBD II log.
Move the Tiptronic's selector lever to position N.
Remove ignition key.
Disconnect battery . → Work instructions after disconnecting the battery
Remove front wheels. → 440519 Removing and reinstalling wheel - chapter on "Removing"
Remove the front wheel-housing liners. → 505619 Removing and reinstalling front wheel-housing liner -
chapter on "Removing"
Remove engine compartment covers. → 700219 Removing and reinstalling front cover (engine
compartment) - chapter on "Removing"
Allow engine to cool down.
Removing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are
described in the notes.
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V8 engine
1. Remove engine guard with transverse strut. → 108019 Removing and installing engine guard - chapter
on "Removing"
Note
The air quality sensor is located on the cover of the radiator tank.
This must be unclipped.
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6. Open the cover of the central electrical system on the left side of
the vehicle. To do this, loosen the four Torx screws.
B+ transfer point
9. Pull the cover of the throttle body up and off.
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Note
In the Cayenne Turbo (M48/50), the boost pressure sensor must
also be disconnected.
11. Release the fastening bolts on the throttle body. To do this, twist
both bolts through 45° in an anti-clockwise direction. The dot on
the bolt must appear as illustrated in the figure.
Boost-pressure sensor
12. Remove the fastening bolts. To do this, take hold of the bolt by
the rubber ring with pliers and pull it out.
13. Pull off the Y-shaped pipe from the throttle body.
Note
If the engine is to be subsequently transported by crane, the
right-hand design cover on cylinder row 5 - 8 should be removed
at this point. → 108319 Removing and installing engine cover -
chapter on "Removing"
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Note
In vehicles with air suspension, the suction line of the compressor
must also be removed on the right air cleaner cover. To do this,
unclip the green cap, press circlip -1- inwards and pull off adapter
-2- .
Filter elements
18. Disconnect the 2 respective oxygen sensor connectors (brown, black) at the left and right of the water
splash panel and unclip the cable from the supports.
Note
In the Cayenne Turbo (M48/50), the support for the vacuum pump must also be undone. To do this,
unscrew the two fastening screws and press the pump forward slightly.
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WARNING
Servo oil is aggressive!
Possible danger of injury or damage (swollen hoses, skin
irritation, danger of slipping, etc.)
20. Empty the servo oil reservoir with a syringe. Next, remove the
hose from the reservoir. Close the open connections with plugs.
DANGER
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22. Disconnect fuel line -1- and line -2- from the carbon canister on Fuel line and carbon canister line
the plenum panel splash panel.
23. Loosen the 3 fastening screws on the left and right spring struts.
The screws are loosened from inside the engine compartment.
Of the 3 screws per spring strut, one is in the plenum panel.
Replace screws.
Note
The drive belt must be slackened so that the air-conditioning
compressor can be removed later.
25. Slacken the drive belt (a/f 30) and remove from the tensioning
roller.
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Note
In the Cayenne Turbo (M48/50), the control lines of the ambient
air valves on the T-piece should be pulled off.
Note
In the case of vehicles with air suspension, the compressed air
line on the spring strut must also be disconnected. Loosen the
line carefully and allow the remaining pressure to escape. Loosen
the threaded joint completely only when the line is fully
depressurised.
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27. Disconnect the brake lines in the wheel well to the left and right.
WARNING
ATF!
Possible danger of injury or damage (swollen hoses, skin
irritation, danger of slipping, etc.)
29. Disconnect the ATF lines on the cooler. To do this, loosen the
fastening screw and pull off the line. Seal open lines with a plug.
Note
In the case of vehicles with Servotronic, an electric plug must
also be removed from the steering gear.
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must not be re-used. Force the steering column up and off the steering gear.
32. Disconnect the electric plug on the steering gear (Servotronic only).
33. Disconnect the heat exchanger coolant lines in the left wheel
housing below. Approx. 2 litres of coolant will flow out when you
do this.
34. Remove the complete exhaust system from the connection point
on the catalytic converter to the tailpipes → 260119 Removing
and installing exhaust system - chapter on "Removing".
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37. Remove the heat shield on the left transmission side. To do so, loosen the 3 fastening screws and take
out the heat protection shield.
Note
Do not loosen nut.
Note
If the transmission is to be separated from the engine after
removal, the two lower fastening screws on the transmission
housing and front cardan shaft should be removed at this point,
since access to the lifting platform will be impaired.
Note
On the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be loosened. To
do this, pull out locking spring -1- on the turbocharger adapter. Then loosen hose clamp -2- of the
pressure pipe on the turbocharger.
Disconnect the connection on the charge air cooler. To do this, remove locking clip -1- and pull off the
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Note
It is easier to remove the air-conditioning compressor from its
installation position when the engine has already been lowered a
little.
If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing
air-conditioning compressor removed during removal of the engine as the replacement engine is
delivered with the new compressor mounted. → 873419 Removing and installing air-conditioning
compressor - chapter on "Removing"
40. Loosen the 3 fastening screws and disconnect the electric plug
from the air-conditioning compressor. Set the air-conditioning
compressor aside.
Note
For installation, it is a good idea to mark the installation position of the front axle carrier diagonally at at
least two places on the body. To do this, place the marks vertically with respect to the floor of the body
using a felt-tip pen (e.g. mark along the front-axle carrier mount with the pen).
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Air-conditioning compressor
42. Mark the installation position of the front axle carrier diagonally at
at least two places on the body.
Note
Because of the high loosening torque, the 6 fastening screws on
the front-axle carrier can now be loosened. Loosen the screws by
a maximum of one turn.
Elevating platform
44. Secure the spring struts. To do this, turn the rubber discs
upwards until they are set under the steering knuckle. Then
tighten the retaining brackets on the wheel hub and elevating
platform.
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45. Loosen the transmission cross member. To do this, loosen the 4 fastening screws -A- .
46. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine
transverse bar with locking screws.
47. Loosen the 4 fastening screws on the front-axle carrier and the 2
fastening screws on the engine transverse bar.
Note
When lowering the engine, make sure that cables or lines do not get
mounted accidentally between engine and body. Thus a second
person should make sure that the cables and lines do not get caught.
48. Lower the lifting platform slowly. When this is done, a second
person should ensure that there is sufficient clearance around
the engine compartment and wheel housings.
Fastening screws for front-axle carrier
and fastening screws for engine
transverse bar
Installing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are
described in the notes.
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Overview of V8 engine
4. Install pre- and main catalytic converters. → 267619 Removing and installing primary catalytic converter -
section on "Removing" [9PAAE1 9PAAE7]→ 267619 Removing and installing primary catalytic converter
- section on "Removing" [9PAAF1 9PAAJ1]
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9. Pre-fit the drive belt. Mount the drive belt on the pulleys as far as
possible.
11. Raise the body to a comfortable working height with the platform
lift.
Note
Oxygen sensor cable for the rear
When moving the unit into the body, ensure that the shift cable is oxygen sensors
on the transmission.
When moving the unit into the body, put the air-conditioning compressor into installation position.
Note
Position the front-axle carrier back in the original, marked
installation position and be careful not to damage adjacent parts.
Air-conditioning compressor
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.
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13. Tighten the 6 new front- combination into the body with the
axle carrier engine carrier lifting platform
screws. For details, see
→ 400619 Removing and
installing front axle carrier
- section on
"Installing" [9PAAJ1]
→ 400619 Removing and
installing front axle carrier
- section on
"Installing" [9PAAE1
9PAAE7 9PAAF1] →
Initial tightening: 120 (89 Fastening screws for front-axle carrier
ftlb.) Nm → Final and engine carrier
tightening - torque
angle: 180 °
Connector to transmission
18.
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Mount selector lever cable. For details see → 371519 Removing and installing selector lever cable -
section on "Installing" [9PAAE1 9PAAF1 9PAAJ1]→ 371519 23 Removing and installing selector lever
cable - section on "Installing" [9PAAE7].
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.
Note
For vehicles with Servotronic, the electric connector on the
steering gear must also be connected.
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21. Fit the heat protection shield on the steering gear by means of 2
fastening screws. → Tightening torque: 10 (7.5 ftlb.) Nm
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ATF lines
→ 386219 23 Removing and installing the line for ATF cooling - section on "Installing" [9PAAE7].
25. Mount the ground point of the generator on the right side
member. → Tightening torque: 20 (15 ftlb.) Nm
29. Install the front transverse strut under the radiators. To do this, tighten the four fastening screws. →
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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.
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33. Fit the electric connections of the spring struts. To do this, connect cable -1- and then fasten supports
-2 and 3- .
34. Lower the vehicle.
35. Mount the three fastening screws on the left and right spring
struts from above (engine compartment side). -arrows- →
Tightening torques for front axle
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37. Connect the servo line to the reservoir and mount the spring
band clamp. Then fill the container with Pentosin.
Note
In the Cayenne Turbo, the support for the vacuum pump must also be screwed into position. →
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45.
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46. Connect the upper left coolant connection piece to the radiator.
The connection piece must engage audibly.
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.
Air-cleaner element
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
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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.
Clipping in lines
50. Attach the vacuum line to the underside of the Y-shaped pipe.
Vacuum line
51. Fit the Y-shaped pipe to the left and right and tighten the hose clamps.
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Note
In the Cayenne Turbo
(M48/50), the boost
pressure sensor -3- must
also be connected.
Subsequent work
Subsequent work
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1. Fill and bleed the cooling system. → 193817 Draining and filling in coolant (includes bleeding) - chapter
on "Filling in"
4. Mount the wiper arms. → 922519 Removing and reinstalling wiper arm - chapter on "Installing".
5. Mount engine compartment covers. → 700219 Removing and reinstalling front cover (engine
compartment) - chapter on "Installing"
8. Bleed offroad stabiliser if necessary. → 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter
on "Adjusting and bleeding" [9PAAJ1]→ 402607 Bleeding the Offroad Stabilisator System (ORS) -
chapter on "Adjusting and bleeding" [9PAAE1 9PAAE7 9PAAF1]
9. Mount front wheels. → 440519 Removing and reinstalling wheel - chapter on "Installing"
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. → 873419 Removing and
reinstalling air-conditioning compressor - chapter on "Installing" and → 870317 Evacuating and filling in
refrigerant - chapter on "filling"
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.
Engine guard
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Required tools
The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions
are noted).
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Lifting platform
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Tools overview
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Tools overview
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Preliminary work
Preliminary work
If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing
air-conditioning compressor removed during removal of the engine as the replacement engine is
delivered with the new compressor mounted. → 873419 Removing and installing air-conditioning
compressor - chapter on "Removing"
Fix steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering
wheel in centre position with steering wheel holder)! If this is not done, the airbag contact unit will have to
be put in centre position after installation of the steering gear! → 945019 Removing and reinstalling
steering-column switch
Position the vehicle at the take-up points provided on a lifting platform. → Lifting the vehicle [9PAAE1
9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1]
Put on the protective covers.
Produce the OBD II log.
Move the Tiptronic's selector lever to position N.
Remove ignition key.
Disconnect battery . → Work instructions after disconnecting the battery
Remove front wheels. → 440519 Removing and reinstalling wheel - chapter on "Removing"
Remove the front wheel-housing liners. → 505619 Removing and reinstalling front wheel-housing liner -
chapter on "Removing"
Remove engine compartment covers. → 700219 Removing and reinstalling front cover (engine
compartment) - chapter on "Removing"
Allow engine to cool down.
Removing engine
Removing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are
described in the notes.
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V8 engine
1. Remove engine guard with transverse strut. → 108019 Removing and installing engine guard - chapter
on "Removing"
Note
The air quality sensor is located on the cover of the radiator tank.
This must be unclipped.
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6. Open the cover of the central electrical system on the left side of
the vehicle. To do this, loosen the four Torx screws.
B+ transfer point
9. Pull the cover of the throttle body up and off.
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Note
In the Cayenne Turbo (M48/50), the boost pressure sensor must
also be disconnected.
11. Release the fastening bolts on the throttle body. To do this, twist
both bolts through 45° in an anti-clockwise direction. The dot on
the bolt must appear as illustrated in the figure.
Boost-pressure sensor
12. Remove the fastening bolts. To do this, take hold of the bolt by
the rubber ring with pliers and pull it out.
13. Pull off the Y-shaped pipe from the throttle body.
Note
If the engine is to be subsequently transported by crane, the
right-hand design cover on cylinder row 5 - 8 should be removed
at this point. → 108319 Removing and installing engine cover -
chapter on "Removing"
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Note
In vehicles with air suspension, the suction line of the compressor
must also be removed on the right air cleaner cover. To do this,
unclip the green cap, press circlip -1- inwards and pull off adapter
-2- .
Filter elements
18. Disconnect the 2 respective oxygen sensor connectors (brown, black) at the left and right of the water
splash panel and unclip the cable from the supports.
Note
In the Cayenne Turbo (M48/50), the support for the vacuum pump must also be undone. To do this,
unscrew the two fastening screws and press the pump forward slightly.
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WARNING
Servo oil is aggressive!
Possible danger of injury or damage (swollen hoses, skin
irritation, danger of slipping, etc.)
20. Empty the servo oil reservoir with a syringe. Next, remove the
hose from the reservoir. Close the open connections with plugs.
DANGER
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22. Disconnect fuel line -1- and line -2- from the carbon canister on Fuel line and carbon canister line
the plenum panel splash panel.
23. Loosen the 3 fastening screws on the left and right spring struts.
The screws are loosened from inside the engine compartment.
Of the 3 screws per spring strut, one is in the plenum panel.
Replace screws.
Note
The drive belt must be slackened so that the air-conditioning
compressor can be removed later.
25. Slacken the drive belt (a/f 30) and remove from the tensioning
roller.
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Note
In the Cayenne Turbo (M48/50), the control lines of the ambient
air valves on the T-piece should be pulled off.
Note
In the case of vehicles with air suspension, the compressed air
line on the spring strut must also be disconnected. Loosen the
line carefully and allow the remaining pressure to escape. Loosen
the threaded joint completely only when the line is fully
depressurised.
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27. Disconnect the brake lines in the wheel well to the left and right.
WARNING
ATF!
Possible danger of injury or damage (swollen hoses, skin
irritation, danger of slipping, etc.)
29. Disconnect the ATF lines on the cooler. To do this, loosen the
fastening screw and pull off the line. Seal open lines with a plug.
Note
In the case of vehicles with Servotronic, an electric plug must
also be removed from the steering gear.
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must not be re-used. Force the steering column up and off the steering gear.
32. Disconnect the electric plug on the steering gear (Servotronic only).
33. Disconnect the heat exchanger coolant lines in the left wheel
housing below. Approx. 2 litres of coolant will flow out when you
do this.
34. Remove the complete exhaust system from the connection point
on the catalytic converter to the tailpipes → 260119 Removing
and installing exhaust system - chapter on "Removing".
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37. Remove the heat shield on the left transmission side. To do so, loosen the 3 fastening screws and take
out the heat protection shield.
Note
Do not loosen nut.
Note
If the transmission is to be separated from the engine after
removal, the two lower fastening screws on the transmission
housing and front cardan shaft should be removed at this point,
since access to the lifting platform will be impaired.
Note
On the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be loosened. To
do this, pull out locking spring -1- on the turbocharger adapter. Then loosen hose clamp -2- of the
pressure pipe on the turbocharger.
Disconnect the connection on the charge air cooler. To do this, remove locking clip -1- and pull off the
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Note
It is easier to remove the air-conditioning compressor from its
installation position when the engine has already been lowered a
little.
If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing
air-conditioning compressor removed during removal of the engine as the replacement engine is
delivered with the new compressor mounted. → 873419 Removing and installing air-conditioning
compressor - chapter on "Removing"
40. Loosen the 3 fastening screws and disconnect the electric plug
from the air-conditioning compressor. Set the air-conditioning
compressor aside.
Note
For installation, it is a good idea to mark the installation position of the front axle carrier diagonally at at
least two places on the body. To do this, place the marks vertically with respect to the floor of the body
using a felt-tip pen (e.g. mark along the front-axle carrier mount with the pen).
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Air-conditioning compressor
42. Mark the installation position of the front axle carrier diagonally at
at least two places on the body.
Note
Because of the high loosening torque, the 6 fastening screws on
the front-axle carrier can now be loosened. Loosen the screws by
a maximum of one turn.
Elevating platform
44. Secure the spring struts. To do this, turn the rubber discs
upwards until they are set under the steering knuckle. Then
tighten the retaining brackets on the wheel hub and elevating
platform.
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45. Loosen the transmission cross member. To do this, loosen the 4 fastening screws -A- .
46. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine
transverse bar with locking screws.
47. Loosen the 4 fastening screws on the front-axle carrier and the 2
fastening screws on the engine transverse bar.
Note
When lowering the engine, make sure that cables or lines do not get
mounted accidentally between engine and body. Thus a second
person should make sure that the cables and lines do not get caught.
48. Lower the lifting platform slowly. When this is done, a second
person should ensure that there is sufficient clearance around
the engine compartment and wheel housings.
Fastening screws for front-axle carrier
and fastening screws for engine
transverse bar
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Installing engine. Page 2 of 21
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Required tools
The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions
are noted).
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Lifting platform
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Tools overview
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Tools overview
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Installing engine
Installing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are
described in the notes.
Overview of V8 engine
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
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support under the oil pan until it touches the oil pan.
3. Fit the transmission onto the engine. → 373527 Removing and mounting the transmission - section on
"Mounting" [9PAAE1 9PAAF1 9PAAJ1] → 373527 AG Removing and mounting the transmission - section
on "Mounting" [9PAAE7] or → 343527 Removing and mounting the transmission - section on
"Mounting" [9PAAE7] → 343527 AG Removing and mounting the transmission - section on
"Mounting" [9PAAE1 9PAAF1 9PAAJ1]
4. Install pre- and main catalytic converters. → 267619 Removing and installing primary catalytic converter -
section on "Removing" [9PAAE1 9PAAE7]→ 267619 Removing and installing primary catalytic converter
- section on "Removing" [9PAAF1 9PAAJ1]
7. Remove the support from under the oil pan and remove the
tipping protection from the engine cross member.
9. Pre-fit the drive belt. Mount the drive belt on the pulleys as far as
possible.
Note
When moving the unit into the body, ensure that the shift cable is Oxygen sensor cable for the rear
on the transmission. oxygen sensors
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
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Note
Position the front-axle carrier back in the original, marked
installation position and be careful not to damage adjacent parts.
Air-conditioning compressor
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.
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17. Connect electric connector -1, 2 and 3- on the transmission and clip in the wiring harness.
18. Mount selector lever cable. For details see → 371519 Removing
and installing selector lever cable - section on
"Installing" [9PAAE1 9PAAF1 9PAAJ1] → 371519 23 Removing
and installing selector lever cable - section on
"Installing" [9PAAE7].
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.
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Note
For vehicles with Servotronic, the electric connector on the
steering gear must also be connected.
24. Connect the ATF lines to the radiator. Remove the plugs and mount the lines. For details see → 386219
Removing and installing the line for ATF cooling - section on "Installing" [9PAAE1 9PAAF1 9PAAJ1]
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→ 386219 23 Removing and installing the line for ATF cooling - section on "Installing" [9PAAE7].
25. Mount the ground point of the generator on the right side
member. → Tightening torque: 20 (15 ftlb.) Nm
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30. Screw the front apron onto the transverse strut. → Tightening
torque: 5 (3.5 ftlb.) Nm
Note
In the case of vehicles with air suspension, the compressed air
lines must also be screwed on.
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33. Fit the electric connections of the spring struts. To do this, connect cable -1- and then fasten supports
-2 and 3- .
35. Mount the three fastening screws on the left and right spring
struts from above (engine compartment side). -arrows- →
Tightening torques for front axle
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Note
In the Cayenne Turbo, the support for the vacuum pump must also be screwed into position. →
Tightening torque: 7.5 ftlb.
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43. Check whether the wiring harness is laid correctly. Close all fixing
clips.
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45. Position and tighten drive belt on all pulleys → 137819 Removing and installing drive belt - section on
"Installing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing drive belt - section on
"Installing" [9PAAE1 9PAAE7].
46. Connect the upper left coolant connection piece to the radiator.
The connection piece must engage audibly.
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.
Air-cleaner element
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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.
Clipping in lines
50. Attach the vacuum line to the underside of the Y-shaped pipe.
Vacuum line
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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.
Boost-pressure sensor
52. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the
left and right fastening bolts. Turn both bolts 45° clockwise.
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Subsequent work
1. Fill and bleed the cooling system. → 193817 Draining and filling in coolant (includes bleeding) - chapter
on "Filling in"
4. Mount the wiper arms. → 922519 Removing and reinstalling wiper arm - chapter on "Installing".
5. Mount engine compartment covers. → 700219 Removing and reinstalling front cover (engine
compartment) - chapter on "Installing"
8. Bleed offroad stabiliser if necessary. → 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter
on "Adjusting and bleeding" [9PAAJ1]→ 402607 Bleeding the Offroad Stabilisator System (ORS) -
chapter on "Adjusting and bleeding" [9PAAE1 9PAAE7 9PAAF1]
9. Mount front wheels. → 440519 Removing and reinstalling wheel - chapter on "Installing"
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. → 873419 Removing and
reinstalling air-conditioning compressor - chapter on "Installing" and → 870317 Evacuating and filling in
refrigerant - chapter on "filling"
12. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "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.
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Engine guard
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Cleaning the engine (washing the engine) Page 2 of 3
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
DANGER
Hot water under high pressure!
Risk of damage for engine components.
Incoming washer-fluid in electric components.
Note
The engine should be washed only if this is absolutely essential for repair work.
Cleaning agents or water should never be applied directly to components that are sensitive to moisture,
such as electric connectors.
When using high-pressure cleaning apparatus, maintain a minimum clearance of 50 cm between the
cleaning lance and the engine component.
For environmental reasons, the engine may only be washed in workshops in which oils are separated
from waste water.
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2. Protect components sensitive to moisture, possibly by covering them with plastic sheeting. Oxygen
sensor connectors must not get wet.
3. Remove any maintenance labels (e.g. oil change schedule tag) and replace after the work is completed.
5. Spray engine components to be cleaned with an appropriate engine cleaning agent and allow it to work
in.
6. Clean the engine. Ensure that a minimum clearance of 50 cm is maintained between the cleaning lance
and engine component. The water temperature must not exceed 80 °C. Remove persistent dirt with a
non-abrasive sponge.
7. Moving components in the engine compartment, such as the hook for the bonnet, must be re-greased.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Note
The special tools that are required are described in the chapter → (Special) tools required for repairing
the M48/00 and M48/50 engines or in the corresponding individual chapters.
Technical values
Technical values
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Note
For information on all tightening torques, see → Tightening torques for Cayenne S (M48/00) and
Cayenne Turbo (M48/50) [9PAAF1 9PAAJ1]→ Tightening torques for Cayenne S (M48/00) and Cayenne
Turbo (M48/50) [9PAAE1 9PAAE7] or the corresponding individual chapters.
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove engine from transmission. → 343527 Removing and refitting the transmission [9PAAE7]
→ 343527 Removing and refitting the transmission [9PAAE1 9PAAF1 9PAAJ1] or → 373527 Removing
and refitting the transmission [9PAAE1 9PAAF1 9PAAJ1]→ 373527 Removing and refitting the
transmission [9PAAE7]
Note
The engine must be disassembled in accordance with the
detailed descriptions in the Technical Manual!
4. Remove wire harness for engine. → 975219 Removing and installing wire harness for engine - section on
"Removing" [9PAAE1 9PAAE7]→ 975219 Removing and installing wire harness for engine - section on
"Removing" [9PAAF1 9PAAJ1]
5. Remove the generator. → 272219 Removing and installing generator - section on "Removing" [9PAAE1
9PAAE7]→ 272219 Removing and installing generator - section on "Removing" [9PAAF1 9PAAJ1]
6. Remove power-steering pump. → 489819 Removing and installing hydraulic pump (Cayenne
Turbo/Cayenne S) - section on "Removing"
7. Remove left additional assembly bracket -2- and right engine carrier -8- . There are also two dowel
sleeves (not shown) on the additional assembly bracket.
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Disassembling engine
Disassembling engine
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1. Remove starter. → 276019 Removing and installing starter - section on "Removing" [9PAAE1 9PAAE7
9PAAF1]→ 276019 21 Removing and installing starter - section on "Removing" [9PAAJ1]
2. Remove knock sensors. → 287219 Removing and installing knock sensor - section on "Removing"
4. Remove water pump. → 195019 Removing and installing coolant pump - section on "Removing"
5. Remove coolant regulator. → 195819 Removing and installing coolant regulator (thermostat) - section on
"Removing"
6. Remove guide and tensioning rails. → 154756 21 Replacing guide and tensioning rails - section on
"Removing"
8. Remove oil spray jets on turbo engine and cap on naturally aspirated engine. → 101321 Removing oil
spray jets for piston cooling [9PAAF1 9PAAJ1]→ 101321 Removing oil spray jets for piston cooling
[9PAAE1 9PAAE7]
Preliminary work
Note
The engine must be disassembled in accordance with the
detailed descriptions in the Technical Manual!
Assembling engine
Assembling engine
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
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Note
The engine must be disassembled in accordance with the
detailed descriptions in the Technical Manual!
1. Fit caps on crankcase. When doing so, make sure that new O-rings are fitted. Tighten the → Tightening
torque: 10 (7.5 ftlb.) Nm .
Note
The bearing shells are available in various tolerance classes. The
classes are indicated by the colour marking on the outside. The
colour marking must match the corresponding colour dot on the
crankshaft. Further details: → Removing and installing crankshaft
2. Insert the bearing shells with the lubricating groove into the upper
part of the crankcase → Inserting the bearing shells . Make sure
the twist locks are positioned correctly. Then lightly oil the
bearing locations.
Colour marking on bearing shell
3. Insert the sickle-shaped washer (make sure of axial bearing play). To do this, insert the two sickle-
shaped washers to the left and right on crankshaft bearing no. 3. Apply some grease (000.043.204.17)
between the crankshaft bearing and the sickle washers so that the sickle washers do not fall down. Each
of the lubricating grooves of the sickle-shaped washers must face outwards → Inserting the sickle-
shaped washers .
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WARNING
The crankshaft is heavy!
There is a danger of
hands being crushed
when inserting the
crankshaft.
4. Insert crankshaft. The connection flange must point towards the back of the engine. Then secure the
crankshaft from falling down using holding bridges 9677. Attach the holding bridges at bearing
locations 3 and 5 → Crankshaft holding bridges . Then screw the fastening screw of the front pulley into
the crankshaft until they just make contact.
Note
The pistons must already be pre-fitted (pistons, piston rings,
connecting rods and fastening material) before performing the
next step.
6. Install piston. To do this, turn the crankshaft with a wrench (a/f 27) until the corresponding lift pin is
pointing straight downwards.
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13. Turn crankcase on the assembly support until the crankshaft is on top.
Note
Con-rod bolts must always be replaced.
14. Tighten con-rod bolts that have been replaced. See → 131019 Removing and installing pistons - section
on "Installing"
16. Screw the two thin centring pins 9321 into the outer fastening
bores on the upper part of the crankcase -Arrows- (crankshaft
not fitted in illustration).
Centring pin
17. Insert the bottom bearing shells into the bottom section of the crankcase (bed plate) and lightly oil
running surfaces. Pay attention to the twist locks when doing so.
18. Make sure the crankcase is ready to be screwed in. Check that the sickle discs are positioned correctly.
Degrease parting surfaces between top and bottom section of crankcase. A totally grease-free product
(e.g. brake cleaner) must be used for this. Then insert a new O-ring at the front of the parting surface.
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Note
Liquid sealant must be applied and screws tightened immediately and without interruption.
The threads and head contact surface of the bearing seat screws (M10 x 1.5 and M12 x 1.5) must be
oiled.
19. Apply Loctite 5970 liquid sealant - 000.043.300.39 (status 11/2005, for details of current sealant, see
Parts Catalogue) to the lower part of the crankcase as shown. The surfaces marked -A- must be cleaned
after fitting.
20. Place bottom section of crankcase into position. When doing so, make sure that the sealing bead is not
destroyed.
21. For details of the tightening sequence for the bottom section of the crankcase and tightening torques,
see → 134819 Removing and installing crankshaft - section on "Installing".
22. Then tighten the four fastening screws on the clutch side → Tightening torque: 23 (17 ftlb.) Nm
-Arrows- .
23. Fit chain drive sprocket on the crankshaft. Unscrew fastening screw on belt pulley. Check that the
feather keys are fitted correctly and push on the chain sprocket with the oil pump drive chain. The
double-tooth row must be facing forwards.
24. Install oil pump. → 172019 Removing and installing oil pump - section on "Installing"
25. Fit guide rail -9- and tensioning rail -6- for the oil pump drive. Push the tensioning rail over the fastening
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Oil pump
pin and engage the guide rail in the bottom section of the crankcase as shown in the illustration.
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26. Fit timing chain cover on oil pump. Tighten the → Tightening
torque: 10 (7.5 ftlb.) Nm .
29. Fit knock sensors. Align the knock sensors as shown in the illustration and tighten the → Tightening
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30. Install thermostat housing. Fit a new O-ring at the water pump
inlet and then insert the thermostat housing. Tighten the two →
Tightening torque: 10 (7.5 ftlb.) Nm .
Cylinder bank 1 - 4
33. Fit cylinder head. The fastening screws must be tightened in the
sequence shown below. The tightening sequences and step-by-
step tightening torques must be observed! For details, see
→ 157023 Removing and installing cylinder head.
Cylinder bank 5 - 8
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34. Fit camshaft housing. Apply a bead of Loctite 5970 liquid sealant - 000.043.300.39 (status 11/2005, for
details of current sealant, see Parts Catalogue) -A- as shown. Then screw two thin centring pins 9321
into two opposing blind holes in the cylinder head. Insert the O-ring -B- into the oil duct. Wipe off any
sealant -C- that emerges as a result of screwing.
Sealant application
35. Position camshaft housing and then unscrew the two centring pins.
36. Tighten the camshaft housing screws in the sequence shown. Don't forget the two hexagon socket head
bolts at the front of the camshaft housing. For details, see → 150323 Removing and installing camshaft
housing.
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Disassembling and assembling engine Page 17 of 24
Note
The bearing locations of the camshafts must be lightly oiled.
Place the camshafts in such a way that the cams are positioned
as shown below!
Positioning camshafts
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Disassembling and assembling engine Page 18 of 24
38. Fit oil return line to camshaft housing 5 - 8. Fit oil return line -1- with a new O-ring -2- . Tighten the four →
Tightening torque: 10 (7.5 ftlb.) Nm -3 and 4- (camshaft housing, cylinder head, crankcase and oil
pan).
39. Position oil feed housing of inlet camshaft and tighten → Tightening torque: 10 (7.5 ftlb.) Nm .
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Disassembling and assembling engine Page 19 of 24
Note
If the camshaft timing gears and camshaft adjusters are removed
completely, the diamond washers and fastening screws must be
replaced!
Deflection rail
ATTENTION
Damage to the camshaft switch-over valve!
Malfunction.
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Disassembling and assembling engine Page 20 of 24
43. Fit timing drive mechanism. Fit guide rail of cylinder bank 5 - 8.
Tighten the leaf spring of the oil pump tensioning rail at the same
time. → 154756 23 Replacing guide and tensioning rails – section
on "Installing"
44. Fit tensioning rail to cylinder bank 1 - 4. Fastening screw for camshaft switch-
over valve
45. Install timing chain. Position the chain on the crankshaft gear
wheel and then fit it over all four camshaft timing gears. To do
this, use both hands to carefully insert the camshaft adjuster and
camshaft timing gear into the timing chain. Screw in fastening
screws of the timing gears loosely to half a turn. Figure
→ Installing timing chain shows procedure with timing-case cover
fitted. Screw in fastening screws of the timing gears loosely to
half a turn.→ 153523 Installing timing chain
46. Fit U-rail. Insert the U-rail into the timing drive mechanism from
above. Tighten the four fastening screws.
Guide rails
49. Place sealing ring over crankshaft using assembly sleeve.
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Disassembling and assembling engine Page 21 of 24
51. Tighten the two upper fastening screws (M6 x 50) and the lower
fastening screws (M6 x 12) by hand. Then tighten the screws
crosswise. → Tightening torque: 10 (7.5 ftlb.) Nm
Assembly sleeve
Note
If the sealing flange on the pulley is slightly rusted, polish the rust
off with a special polishing pad (e.g. Never Dull).
Note
A feather key is inserted into the crankshaft. When fitting the Crankshaft belt pulley
pulley, ensure that the feather key slots into the groove in the pulley.
53. Fit crankshaft belt pulley.→ 137619 Removing and installing crankshaft belt pulley - section on "Installing"
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Disassembling and assembling engine Page 22 of 24
54. Fit oil pan. → 175023 Oil pan installed (includes sealing)
Note
To remove the play from the timing chain for the setting process,
the crankshaft must be positioned approx. 45° in front of the TDC
of cylinder 1 before turning!
58. Install the camshaft housing cover on both cylinder banks Installation location of chain tensioner
→ 159123 Installing the camshaft housing cover.
59. Fit water pump. → 195019 Removing and installing coolant pump - section on "Installing"
Subsequent work
Subsequent work
1. Fit left additional assembly bracket -2- and right engine carrier -8- . There are still two dowel sleeves (not
shown) on the additional assembly bracket.
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Disassembling and assembling engine Page 23 of 24
2. Fit power-steering pump. → 489819 Removing and installing hydraulic pump (Cayenne Turbo/Cayenne
S) - section on "Installing"
3. Fit generator. → 272219 Removing and installing generator - section on "Installing" [9PAAE1 9PAAE7]
→ 272219 Removing and installing generator - section on "Installing" [9PAAF1 9PAAJ1]
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Disassembling and assembling engine Page 24 of 24
4. Fit wire harness for engine. → 975219 Removing and installing wire harness for engine - section on
"Installing" [9PAAE1 9PAAE7]→ 975219 Removing and installing wire harness for engine - section on
"Installing" [9PAAF1 9PAAJ1]
5. Refit engine on transmission. → 343527 Removing and refitting the transmission [9PAAE7]→ 343527
Removing and refitting the transmission [9PAAE1 9PAAF1 9PAAJ1] or → 373527 Removing and refitting
the transmission [9PAAE1 9PAAF1 9PAAJ1]→ 373527 Removing and refitting the
transmission [9PAAE7]
6. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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The most important working regulations and warning notes Page 2 of 11
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Folder 1
Group 1 - Engine
DANGER
Suspended load!
Risk of serious crushing and injury
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
DANGER
Danger of injury from incorrect use of tools and from falling loads!
Danger of crushing from heavy loads!
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→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ Never use defective lifting equipment (bent or damaged tools must not be used or repaired. Always
replace these tools). Check tools for signs of damage before use.
→ Only use lifting equipment tested and approved by Porsche. Home-made and auxiliary constructions
result in improper use and are dangerous.
→ The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e.g.
from chains or cables) will damage the transport eyebolt, which must then be replaced. Extreme cases
of improper use can break the transport eyebolt.
→ Tools and lifting equipment must always be used properly. Improper use or dangerous home-made
constructions can break tools and result in falling loads.
→ Wear protective gloves.
DANGER
Danger of poisoning from silicone, grease and oil!
Danger of poisoning and damage to skin
Note
When working on the crank mechanism, absolute cleanliness is essential.
Only the auxiliary and assembly equipment recommended for the repair job may be used for the
particular assembly work.
Only the auxiliary materials recommended by Porsche (such as lubricants or sealants) may be used.
All screw fittings must be tightened according to the prescribed torque or torque angle.
DANGER
Danger of poisoning from silicone, grease and oil!
Danger of poisoning and damage to skin
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DANGER
Danger of injury from rotating components and belt drive!
Risk of severe hand injuries.
WARNING
Do not remove the drive belt when the engine is warm!
Risk of damage or deformation!
→ Drive belts should only be removed when they have cooled down.
DANGER
Danger of injury from running radiator fans (electric fans)!
Risk of severe hand injuries.
→ The vehicle fans can continue running or start up when the ignition is switched off.
→ The power supply to the fans must be disconnected before starting work on the radiator or radiator fans.
(Remove fuse → Fuse carrier [9PAAE1 9PAAE7 9PAAF1] → Fuse carrier [9PAAD1 9PAAD7 9PAAJ1]).
Note
Work on the crank mechanism/pistons must be carried out very carefully and in clean conditions.
During work interruptions, the open engine or components must be covered to protect them from dirt.
Only processing materials (silicones, oils, greases, etc.) approved by Porsche may be used.
All screw fittings must be tightened according to the prescribed torque or torque angle.
Note
Only processing materials (silicones, oils, greases, etc.) approved by Porsche may be used.
All screw fittings must be tightened according to the prescribed torque or torque angle.
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DANGER
Danger of poisoning from silicone, grease and oil!
Danger of poisoning and damage to skin
Note
Work on the valve drive must be carried out very carefully and in clean conditions.
During work interruptions, the open engine or components must be covered to protect them from dirt.
Only the auxiliary materials recommended by Porsche (such as lubricants or sealants) may be used.
All screw fittings must be tightened according to the prescribed torque or torque angle.
Group 17 - Lubrication
WARNING
Engine oil is toxic.
Danger of poisoning!
WARNING
Danger of scalding from hot oil!
→ Engine oil and components of the oil circuit can become very hot!
→ Allow engine and components to cool down.
→ Avoid contact with the skin and eyes.
→ Wear suitable protective clothing.
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WARNING
Oil is combustible!
Risk of fire due to oil and hot components (exhaust manifold, etc.)
→ Do not pour engine oil over very hot components (e.g. turbocharger).
→ Never place cloths soaked with oil on hot engine components.
→ In case of fire, use CO2 or dry powder fire extinguishers.
Note
Only oils with the appropriate viscosity and approved by Porsche may be used.
During an oil change, the old oil must be drained from the engine via the drain plugs provided. Extraction
by suction is not recommended.
Engine oil and oil filters must be disposed of according to the respective, applicable national laws.
Seals in the oil circuit must be replaced by new ones following disassembly.
Group 19 - Cooling
ATTENTION
Danger of poisoning!
Coolant additives and cleaning liquids are toxic.
ATTENTION
Danger of scalding with hot coolant!
→ Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause
scalding.
→ The cooling system must be depressurised before being opened.
→ Allow engine to cool down.
DANGER
The vehicle fans can continue running or start up automatically.
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→ The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or
the belt drive. → Disconnect fuse carrier [9PAAE1 9PAAE7 9PAAF1] → Disconnect fuse carrier [9PAAD1
9PAAD7 9PAAJ1] or battery → Work instructions after disconnecting the battery
ATTENTION
Risk of damaging the cooling system!
→ Do not relieve the system pressure of the cooling system and then run the engine.
→ Relieving the system pressure and subsequently starting the engine can cause severe damage to
components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling
system to cool down before starting the engine again.
Note
The coolant filled in at the factory is intended to suffice for the entire service life. As long as the coolant is
not contaminated by foreign bodies or other fluids it need not be changed.
Different coolant additives must not be mixed and doing so may damage the cooling system. Only use
original Porsche coolant additives.
The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50 : 50
(coolant additive : water). This mixing ratio provides optimum corrosion and antifreeze protection.
Coolant additives, coolants and cleaning agents must be disposed of according to the respective,
applicable national laws.
Seals in the cooling system must be replaced by new ones following disassembly.
Information
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
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→ 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.
DANGER
Danger of fire from fuel!
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
ATTENTION
Danger of burns from very hot components (turbocharger, exhaust manifold)!
Note
After the connecting clamps in the exhaust system have been released, they must always be replaced.
During assembly work on the exhaust system, ensure that the components are aligned and installed
correctly.
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DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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ATTENTION
The oxygen sensor may be damaged if handled incorrectly.
Change in engine emissions.
Damage to the environment.
Check Engine lamp may come on.
→ Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread
grease must never come into contact with the connector.
→ Protect sensors - before and after fitting - against mechanical shocks.
→ Sensors that were dropped on the floor must not be used owing to the risk of a broken ceramic insulator.
→ The cables must not be twisted or kinked when the sensors are screwed in. Avoid pulling on the cable
and connector.
→ Cleanliness in the housing of the plug connections is of utmost importance for the oxygen sensor to
function properly. Particles of dirt can impair the function of the oxygen sensor. The connector must
therefore be protected against any and all types of soiling.
→ Sensors with a soiled or damaged connector must no longer be used.
→ Protect the cables and plugs when carrying or moving the exhaust system with the sensors already
fitted.
→ High-pressure cleaning equipment must not be used in the area of the sensors and plug connections.
→ Contact and corrosion agents, e.g. Stabilant, must not be applied to the plug contacts of the oxygen
sensors.
ATTENTION
Danger of injury from heavy loads!
→ When working on the exhaust system, it must be appropriately secured against falling or lowering.
→ Never use defective lifting equipment.
→ Only use lifting equipment tested and approved by Porsche.
ATTENTION
Engine exhaust gas!
Danger of poisoning!
→ Only operate the engine with an appropriate exhaust gas extraction system.
ATTENTION
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Note
After the connecting clamps in the exhaust system have been released, they must always be replaced.
During assembly work on the exhaust system, ensure that the components are aligned and installed
correctly.
ATTENTION
High-voltage ignition system!
Danger of electric shocks!
This can cause cardiac irregularities.
→ When working on the ignition system, the ignition key must be removed from the ignition lock.
→ The ignition system must be disconnected from the power supply before starting work on it.
→ Only connect/disconnect lines or plugs when the ignition is switched off.
→ Only connect measuring devices when the ignition is switched off.
Note
The ignition system must be disconnected from the power supply before starting work on it.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Securing engine on assembly support Page 2 of 4
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Lift the engine with a workshop crane. → 10 Lifting the engine with a workshop crane
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DANGER
Suspended load!
Risk of serious crushing and injury
DANGER
Danger of injury from incorrect use of tools and from falling loads!
Danger of crushing from heavy loads!
→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ Never use defective lifting equipment (bent or damaged tools must not be used or repaired. Always
replace these tools). Check tools for signs of damage before use.
→ Only use lifting equipment tested and approved by Porsche. Home-made and auxiliary constructions
result in improper use and are dangerous.
→ The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e.g.
from chains or cables) will damage the transport eyebolt, which must then be replaced. Extreme cases
of improper use can break the transport eyebolt.
→ Tools and lifting equipment must always be used properly. Improper use or dangerous home-made
constructions can break tools and result in falling loads.
→ Wear protective gloves.
Note
Some repair jobs involve suspending the engine on a suitable assembly support.
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\1001IN_0.htm 17.08.2011
Determining the operating cycle of cylinder 1 Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Determining the operating cycle of cylinder 1 with the "cylinder pipe" dead centre finder.
ATTENTION
Risk of damage to timing drive mechanism!
Never twist the crankshaft against the direction of rotation.
Remove and install the chain tensioner only in overlapping TDC.
Never twist the crankshaft when the chain tensioner is removed.
Never twist the camshafts when the chain tensioner is removed.
Never apply forces across the camshafts in the timing drive mechanism.
Always counter the sprocket wheels when performing assembly work on them.
→ Forces from the valve drive can cause the timing chain to jump over or tilt.
Note
An alternative method for determining the overlapping TDC is the "cylinder pipe" (dead centre finder). This
tool is part of the pressure-loss tester WE 1066, Workshop Installation Manual 3.1.4.
For some tasks, it is necessary to be familiar with the position of the piston in the cylinder (ignition TDC,
overlapping TDC).
1. Remove spark plugs for the relevant cylinder 3.→ 287055 Replacing spark plugs
2. The dead centre finder or "cylinder pipe" consists of glass tubes (inspection glass) with pistons -1- , a
hose and a rubber taper -2- .
3. The rubber taper is pressed onto the spark plug hole. The inspection glass is either held by an assistant
→ Tool setup - dead centre finder or secured vertically using a magnet so that it is clearly visible.
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Determining the operating cycle of cylinder 1 Page 3 of 6
Tool setup - dead centre finder Dead centre finder - "cylinder pipe"
Top piston
4. If the engine is then turned in the direction of rotation on the crankshaft, the piston in the inspection glass
is pressed upward in the compression cycle → Top piston , and moves back down again immediately
once the TDC has been reached. The piston remains down in the inspection glass in the overlapping
TDC → Bottom piston .
Note
This method only works in ignition rod modules that have rubber seals facing the spark-plug recess.
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Determining the operating cycle of cylinder 1 Page 4 of 6
Bottom piston
1. Remove spark plugs for the relevant cylinder 3.→ 287055
Replacing spark plugs
V8 spark plugs
2. Find ignition TDC of cylinder 1. To do this, insert the ignition rod
module of the first cylinder into the corresponding opening in the
valve cover and press in firmly.
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Determining the operating cycle of cylinder 1 Page 5 of 6
Note
If the crankshaft is then turned through 180°, the piston in
cylinder 1 will be located in the bottom dead centre (BDC). The
emission cycle then follows.
4. Then twist the crankshaft until the fixing bore on the crankshaft
belt pulley is aligned with the bore in the timing case cover. The
engine is now located in the ignition TDC of cylinder 1.
Note
This method only works in ignition rod modules that have rubber seals facing the spark-plug recess.
V8 spark plugs
2. Find overlapping TDC of cylinder 1. To do this, insert the ignition
rod module of the first cylinder into the corresponding opening in
the valve cover and press in firmly.
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Determining the operating cycle of cylinder 1 Page 6 of 6
out
Note
If the crankshaft is then turned through 180°, the piston in
cylinder 1 will be located in the bottom dead centre (BDC). The
compression cycle then follows.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Tightening torques for Cayenne S (M48/00) and Cayenne Turbo (M48/50) Page 2 of 14
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Information
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Tightening torques for Cayenne S (M48/00) and Cayenne Turbo (M48/50) Page 3 of 14
V8 engine
Note
This torque list is organised according to component groups in the same way as service numbering.
The tightening sequences are indicated in the figures in the corresponding chapters, and it is essential to
observe them.
The most important torques are specified at the end of the respective chapters.
The torques in the table below generally apply to screws which are not specifically listed.
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M6 10 M6 13
M8 23 M8 33
M10 45 M10 65
M10 x 1.25 50 M10 x 1.25 70
M12 80 M12 115
M12 x 1.25 90 M12 x 1.25 125
M12 x 1.5 85 M12 x 1.5 120
M14 130 M14 180
M16 200 M16 280
Tightening sequences
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Drive plate to crankshaft M10 x 22 60 (44) + 90° (always replace screws with
new ones!)
Tightening sequences
Note
The exterior fastening screws must have a quality of 10.9.
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Group 17 - Lubrication
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Group 19 - Cooling
Tightening sequences
Thermostat housing
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Water pump
Tightening sequences
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Suction module
Tightening sequences
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Exhaust manifold
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\1001IN_2.htm 17.08.2011
Lifting the engine with a workshop crane Page 2 of 7
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Special tools
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Lifting the engine with a workshop crane Page 3 of 7
Suspending device
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Lifting the engine with a workshop crane Page 4 of 7
Fastening screws
2. Lift the cover slightly with both hands at the side pointing towards
the intake system until it is released from its holder.
Unclipping cover
3. Lift the front of the design cover and remove it.
DANGER
Suspended load!
Risk of serious crushing and injury
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Lifting the engine with a workshop crane Page 5 of 7
DANGER
Danger of injury from incorrect use of tools and from falling loads!
Danger of crushing from heavy loads!
→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ Never use defective lifting equipment (bent or damaged tools must not be used or repaired. Always
replace these tools). Check tools for signs of damage before use.
→ Only use lifting equipment tested and approved by Porsche. Home-made and auxiliary constructions
result in improper use and are dangerous.
→ The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e.g.
from chains or cables) will damage the transport eyebolt, which must then be replaced. Extreme cases
of improper use can break the transport eyebolt.
→ Tools and lifting equipment must always be used properly. Improper use or dangerous home-made
constructions can break tools and result in falling loads.
→ Wear protective gloves.
Note
Place a cloth between the secondary air pump bracket and design cover to avoid scratching the cover.
Note
Never use defective lifting equipment (bent or damaged tools must not be used or repaired -3- . Always
replace these tools). Check tools for signs of damage before use.
The transport eyebolt must only be pulled straight -1- . Never use
side or transverse force on the transport eyebolt -2- because this
can damage the transport eyebolt.
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Lifting the engine with a workshop crane Page 6 of 7
-arrow- .
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Lifting the engine with a workshop crane Page 7 of 7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Suspending device
file://C:\POSES\data\rl\2\9PA\1001IN_5.htm 17.08.2011
Supporting the engine on the body Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
file://C:\POSES\data\rl\2\9PA\1001IN_7.htm 17.08.2011
Supporting the engine on the body Page 3 of 6
WARNING
Danger of injury from falling loads!
Drive line components (engine, transmission, etc.) can fall down.
→ Before starting work, check the body for structural damage (accident, corrosion, etc.). The load capacity
of the wing mounting points must not be restricted.
→ Do not apply excessive force (e.g. a high screw torque) to supported units.
→ Units must not be supported on the body over an extended period of time.
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Supporting the engine on the body Page 4 of 6
DANGER
Danger of injury from incorrect use of tools and from falling loads!
Danger of crushing from heavy loads!
→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ Never use defective lifting equipment (bent or damaged tools must not be used or repaired. Always
replace these tools). Check tools for signs of damage before use.
→ Only use lifting equipment tested and approved by Porsche. Home-made and auxiliary constructions
result in improper use and are dangerous.
→ The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e.g.
from chains or cables) will damage the transport eyebolt, which must then be replaced. Extreme cases
of improper use can break the transport eyebolt.
→ Tools and lifting equipment must always be used properly. Improper use or dangerous home-made
constructions can break tools and result in falling loads.
→ Wear protective gloves.
Note
Never use defective lifting equipment (bent or damaged tools must not be used or repaired -3- . Always
replace these tools). Check tools for signs of damage before use.
The transport eyebolt must only be pulled straight -1- . Never use
side or transverse force on the transport eyebolt -2- because this
can damage the transport eyebolt.
Note
The engine must be supported on the body for some repair work
on the front axle and engine bearings.
Note
When setting up the suspending device, make sure not to scratch
or damage adjacent components.
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Supporting the engine on the body Page 5 of 6
2. 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.
Note
Place a cloth between secondary air pump bracket and design cover to avoid scratching the cover.
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Supporting the engine on the body Page 6 of 6
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\1001IN_7.htm 17.08.2011
(Special) tools required for repairing the M48/00 and M48/50 engines Page 2 of 12
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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(Special) tools required for repairing the M48/00 and M48/50 engines Page 3 of 12
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(Special) tools required for repairing the M48/00 and M48/50 engines Page 4 of 12
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(Special) tools required for repairing the M48/00 and M48/50 engines Page 5 of 12
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(Special) tools required for repairing the M48/00 and M48/50 engines Page 6 of 12
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(Special) tools required for repairing the M48/00 and M48/50 engines Page 7 of 12
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(Special) tools required for repairing the M48/00 and M48/50 engines Page 8 of 12
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(Special) tools required for repairing the M48/00 and M48/50 engines Page 9 of 12
(Special) tools required for repairing the M48/00 and M48/50 engines
Tools overview 1
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(Special) tools required for repairing the M48/00 and M48/50 engines Page 10 of 12
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(Special) tools required for repairing the M48/00 and M48/50 engines Page 11 of 12
Tools overview 2
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(Special) tools required for repairing the M48/00 and M48/50 engines Page 12 of 12
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\1001WM_0.htm 17.08.2011
Completing reconditioned engine Page 2 of 2
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Note
In order to replace the old, removed engine with a new one, some re-fitting work must be done.
Starting point for re-fitting work: old engine is secured to assembly support and the new one is in the
transport cradle.
At higher mileages, components (cooling hoses, clips etc.) must be checked for damage and, if
necessary, replaced.
1. Remove numerous transport plugs for water and vacuum connection pieces of the new engine.
2. Check that all leads and hoses between the engines have been re-fitted and no component has been
forgotten.
3. Depending on the transmission version, the drive plate → 136319 Removing and installing drive plate for
torque converter [9PAAE1 9PAAF1 9PAAJ1]→ 136319 Removing and installing drive plate for torque
converter [9PAAE7] or flywheel → 136019 Removing and installing flywheel [9PAAE7]→ 136019
Removing and installing flywheel [9PAAE1 9PAAF1 9PAAJ1] must be re-fitted.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\100433_1.htm 17.08.2011
Replacing crankcase Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove wire harness for engine. → 975219 Removing and installing wire harness for engine - section on
"Removing" [9PAAE1 9PAAE7]→ 975219 Removing and installing wire harness for engine - section on
"Removing" [9PAAF1 9PAAJ1]
3. Remove the generator. → 272219 Removing and installing generator - section on "Removing" [9PAAE1
9PAAE7]→ 272219 Removing and installing generator - section on "Removing" [9PAAF1 9PAAJ1]
4. Remove power-steering pump. → 489819 Removing and installing hydraulic pump (Cayenne
Turbo/Cayenne S) - section on "Removing"
5. Remove left additional assembly bracket -2- and right engine carrier -8- . There are still two dowel
sleeves (not shown) on the additional assembly bracket.
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Replacing crankcase Page 3 of 8
6. Remove starter. → 276019 Removing and installing starter - section on "Removing" [9PAAE1 9PAAE7
9PAAF1]→ 276019 21 Removing and installing starter - section on "Removing" [9PAAJ1]
7. Remove knock sensors. → 287219 Removing and installing knock sensor - section on "Removing"
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Replacing crankcase Page 4 of 8
9. Remove water pump. → 195019 Removing and installing coolant pump - section on "Removing"
10. Remove coolant regulator. → 195819 Removing and installing coolant regulator (thermostat) - section on
"Removing"
11. Remove guide and tensioning rails. → 154756 21 Replacing guide and tensioning rails - section on
"Removing"
12. Remove crankshaft. → 134819 Removing and installing crankshaft - section on "Removing"
13. Remove oil spray jets on turbo engine and cap on naturally aspirated engine. → 101321 Removing oil
spray jets for piston cooling [9PAAF1 9PAAJ1]→ 101321 Removing oil spray jets for piston
cooling [9PAAE1 9PAAE7]
Information
Component overview
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Replacing crankcase Page 5 of 8
1 - Crankcase, top
2 - Closure cap
3 - Seal
4 - Closure cap
5 - Screw → Tightening torque: 10 (7.5 ftlb.) Nm
6 - Screw plug → Tightening torque: 10 (7.5 ftlb.) Nm
7 - Sealing ring
8 - Sealing ring (not marked in illustration)
9 - Screw plug → Tightening torque: 75 (56 ftlb.) Nm
10 - Oil spray jets on turbo engine and cap on naturally aspirated engine
11 - Dowel sleeves
Replacing crankcase
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Replacing crankcase Page 6 of 8
Replacing crankcase
ATTENTION
Risk of damage to cylinder liners on new crankcase if the old pistons are used.
Piston separation could cause the dimensions of the old piston to be unacceptably large
compared with the new cylinder bore.
Risk of piston and cylinder-liner scoring if old, worn pistons are used.
→ The piston rings on the pistons must always be replaced when replacing the crankcase.
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
Note
The bearing shells of the main and connecting-rod bearings must be replaced on vehicles with high mileage.
Coolant pipe
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Replacing crankcase Page 7 of 8
Coolant guide
1 - Distributor pipe
2 - Temperature sensor
3 - Sealing ring
4 - Screw plug → Tightening torque: 30 (22 ftlb.) Nm
5 - Fastening screws on distributer pipe → Tightening torque: 10 (7.5 ftlb) Nm
6 - Gasket; replace
7 - Sealing ring; check and replace if necessary
8 - Coolant pipe
3. Re-fit crankcase. When doing so, watch out for dowel sleeves and studs.
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Replacing crankcase Page 8 of 8
Subsequent work
Subsequent work
1. Assemble engine. → Assembling engine
2. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\101055_0.htm 17.08.2011
Testing pressure loss from the engine Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Spark plugs
2. Position cylinder to be tested to ignition TDC and remove tool.
There are two ways of ascertaining the compression cycle in V8
engines with sealed-off ignition rod modules. → Determining the
operating cycle of cylinder 1
file://C:\POSES\data\rl\2\9PA\101802_0.htm 17.08.2011
Testing pressure loss from the engine Page 3 of 5
Information
Test evaluation
The test does not show any meaningful result on a new engine (i.e. one that hasn't been run in).
A difference in pressure loss between the individual cylinders of approx. 5% is not significant.
If the test shows an excessive loss of pressure (> 30%), a few drops of oil can be sprayed into the
combustion chamber. Repeat the test. If the loss in pressure is now significantly less, the seal between
the piston and cylinder is damaged.
The air that is escaping causes hissing noises, which provide information about the component that is
causing the damage.
If the limit values are exceeded, the engine must be started and the test repeated.
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Testing pressure loss from the engine Page 4 of 5
ATTENTION
Danger of damage or injury if pressure loss tester is operated incorrectly
→ Ensure that operational steps and tips from the tool instruction manual for the Bosch tester are observed
at all times.
WARNING
Danger of injury!
The crankshaft can turn because of the pressure in the cylinder.
Note
The check for loss of pressure can be used to assess the mechanical condition of a combustion engine.
The percentage leakage quantity can be used to establish whether the leaks in the combustion chamber
in question are so large that the combustion chamber must be repaired.
The worn components (e.g. piston rings) can be identified by the compressed air that is escaping.
1. Screw in the test hose by hand into the spark plug thread and
tighten it by hand.
2. Connect the pressure loss tester to the compressed air system.
Test hose
3. Adjust the scale. To do this, insert the test nozzle at the front into the device.
4. Turn the adjusting wheel until the scale pointer is at the "cal." marking or "23%". The pressure is then
equal in the two test chambers of the tool.
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Testing pressure loss from the engine Page 5 of 5
Adjusting wheel
5. Remove test hose and check that the pointer falls back. Connect
the test hose. The value that is displayed should not be greater
than 30%. If the loss in pressure is greater, it can be assumed
that the engine needs an overhaul.
6. Interrupt the compressed air supply and unscrew the test hose.
Firing order: 1 - 3 - 7 - 2 - 6 - 5 - 4 - 8
Check for loss of pressure
Subsequent work
Subsequent work
1. Remove the test hose once the test is complete and install the
spark plugs. For tightening torques see → 287055 Replacing
spark plugs
Spark plugs
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\101802_0.htm 17.08.2011
Checking compression of cylinders Page 2 of 7
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Open the bonnet.
WARNING
Risk of electric shocks from high-voltage ignition system and
danger of damage to ignition rod modules!
Connected ignition rod modules can be damaged.
file://C:\POSES\data\rl\2\9PA\101902_0.htm 17.08.2011
Checking compression of cylinders Page 3 of 7
ATTENTION
Risk of damage to components that affect the exhaust system!
Unburnt injected fuel enters the exhaust system.
3. Remove the fuses -7- for the ignition rod modules -8- and injection system.
Spark plugs
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Checking compression of cylinders Page 4 of 7
Information
Note
A test document is created when a compression test is performed.
In order to prevent misuse, vehicle ID, date and current mileage must be entered.
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Checking compression of cylinders Page 5 of 7
Test sheet
Note
The compression test can only provide an indication as to whether the tested cylinder is working or not
working properly. The cause of any loss can be further isolated by a pressure loss test.→ 101802 Testing
pressure loss
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Checking compression of cylinders Page 6 of 7
Note
Once the starter is activated, it switches on the engine for approx.
seven seconds.
The vehicle voltage must not drop below 12 V during the test.
2. Have the starter actuated by a second person. Testing of this cylinder is complete when the needle of
the test device ceases to rise. Keep the accelerator pedal fully depressed.
Subsequent work
Subsequent work
Spark plugs
file://C:\POSES\data\rl\2\9PA\101902_0.htm 17.08.2011
Checking compression of cylinders Page 7 of 7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\101902_0.htm 17.08.2011
Removing and installing engine carrier Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Support engine on the body.→ Supporting engine on the body.
2. Remove engine guard. → 108019 Removing and installing engine guard - chapter on "Removing"
3. Remove front axle until the engine carrier can be removed. → 400619 Removing and installing front-axle
carrier - chapter on "Removing" [9PAAJ1]→ 400619 Removing and installing front-axle carrier - chapter
on "Removing" [9PAAE1 9PAAE7 9PAAF1]
Information
Component overview
file://C:\POSES\data\rl\2\9PA\103019_0.htm 17.08.2011
Removing and installing engine carrier Page 3 of 5
Component overview
file://C:\POSES\data\rl\2\9PA\103019_0.htm 17.08.2011
Removing and installing engine carrier Page 4 of 5
WARNING
Danger of injury!
→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ Never use defective lifting equipment.
→ Only use lifting equipment tested and approved by Porsche.
→ The components are very heavy. There is a danger of crushing.
→ Wear protective gloves.
→ Please observe general warning notes.
Note
This task can only be performed if the engine has been removed or suspended on the body.
Note
Do not undo the engine mounts on the engine.
If the engine mounts have been undone on the engine, they must be aligned using the engine carrier.
→ 103519 Removing and installing engine mount
Engine carrier
1. Undo the two fastening screws → Fastening screws for engine mounting to the left and right on the
hydraulic mounts.
2. Undo the two fastening screws from the engine carrier to the body and remove the engine carrier.
file://C:\POSES\data\rl\2\9PA\103019_0.htm 17.08.2011
Removing and installing engine carrier Page 5 of 5
Subsequent work
Subsequent work
1. Screw in new fastening screws for securing the engine carrier to the body. → Initial tightening: 89 ftlb.
→ Torque angle: 180 °
2. Install front axle. → 400619 Removing and installing front-axle carrier - chapter on "Installing" [9PAAJ1]
→ 400619 Removing and installing front-axle carrier - chapter on "Installing" [9PAAE1 9PAAE7 9PAAF1]
3. Install engine guard. → 108019 Removing and installing engine guard - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\103019_0.htm 17.08.2011
Removing and installing engine mounting Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Support engine on the body.→ Supporting engine on the body.
2. Remove engine guard. → 108019 Removing and installing engine guard - chapter on "Removing"
3. Remove front axle until the engine carrier can be removed. → 400619 Removing and installing front-axle
carrier - chapter on "Removing" [9PAAJ1]→ 400619 Removing and installing front-axle carrier - chapter
on "Removing" [9PAAE1 9PAAE7 9PAAF1]
Information
Component overview
file://C:\POSES\data\rl\2\9PA\103519_0.htm 17.08.2011
Removing and installing engine mounting Page 3 of 5
Component overview
file://C:\POSES\data\rl\2\9PA\103519_0.htm 17.08.2011
Removing and installing engine mounting Page 4 of 5
WARNING
Danger of injury!
→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ Never use defective lifting equipment.
→ Only use lifting equipment tested and approved by Porsche.
→ The components are very heavy. There is a danger of crushing.
→ Wear protective gloves.
→ Please observe general warning notes.
Note
This task can only be performed in the Cayenne S (M48/00) if the engine has been removed or
suspended on the body. This description covers suspension on the body.
The engine must be removed on the Cayenne Turbo (M48/50) → 100119 Removing and installing V8 4.5
l engine - section on "Removing". The turbochargers are removed next. → 213021 Removing
turbocharger - section on "Removing" [9PAAF1 9PAAJ1]→ 213021 21 Removing turbocharger - section
on "Removing" [9PAAE1 9PAAE7].
1. Undo the two fastening screws -Arrows- to the left and right on
the hydraulic mounts.
Hydraulic mount
2. Undo the two fastening screws from the engine carrier to the
body and remove the engine carrier. -Centre arrow-
Engine carrier
file://C:\POSES\data\rl\2\9PA\103519_0.htm 17.08.2011
Removing and installing engine mounting Page 5 of 5
Note
The engine mounts must be aligned using the engine carrier.
1. Position engine mounts on the support arm. When doing so, note the positioning pin on the mount. It
must engage in the recess on the support arm.
2. Position new fastening nuts and screw them on so that the positioning pin cannot pop out. Do not tighten
the fastening nuts.
Subsequent work
Subsequent work
1. Screw in new fastening screws for securing the engine carrier to the body. → Initial tightening: 89 ftlb.
→ Torque angle: 180 °
2. Install front axle. → 400619 Removing and installing front-axle carrier - chapter on "Installing" [9PAAJ1]
→ 400619 Removing and installing front-axle carrier - chapter on "Installing" [9PAAE1 9PAAE7 9PAAF1]
3. Install engine guard. → 108019 Removing and installing engine guard - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\103519_0.htm 17.08.2011
Removing and installing engine guard Page 2 of 4
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Overview
file://C:\POSES\data\rl\2\9PA\108019_0.htm 17.08.2011
Removing and installing engine guard Page 3 of 4
Front screws
2. Remove rear engine guard. To do this, loosen the fastening screws on the transmission cross member
-1- and the screws on the traverse strut -2- .
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Removing and installing engine guard Page 4 of 4
Rear screws
1. Install the rear engine guard. To do this, screw in the front
fastening screws -2- and rear fastening screws -1- .
2. Tighten front fastening screws -3- and rear fastening screws -2-
and -1- → Tightening torque: 6.5 ftlb. .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\108019_0.htm 17.08.2011
Removing and installing design cover. Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Overview
Note
A special paint is applied to the covers for reasons of appearance.
When the engine is washed, a minimum clearance of 50 cm must be maintained between the cleaning
apparatus lance and the covers.
Small scratches on the paintwork can be touched up with a special touch-up applicator.
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Removing and installing design cover. Page 3 of 8
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Removing and installing design cover. Page 4 of 8
Note
Place a cloth between secondary air pump bracket and design cover to avoid scratching the cover.
1. Remove engine compartment cover on the right and rear. → 700219 Removing and installing front cover
(engine compartment)
5. Unscrew the four fastening screws on the design cover (picture 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.
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Removing and installing design cover. Page 5 of 8
Note
Place a cloth between secondary air pump and design cover to avoid scratching the cover.
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Removing and installing design cover. Page 6 of 8
Note
Place a cloth between secondary air pump bracket and design cover to avoid scratching the cover.
3. Tighten the four fastening screws on the ignition coils (illustration shows side 5-8). → Tightening torque:
3.5 ftlb.
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Removing and installing design cover. Page 7 of 8
Note
Place a cloth between secondary air pump and design cover to avoid scratching the cover.
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Removing and installing design cover. Page 8 of 8
pump
1. Press the 4 rubber elements in the cover onto the 4 ball head
supports. The mounts must be felt to engage.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\108319_0.htm 17.08.2011
Removing and installing pistons Page 2 of 9
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Information
file://C:\POSES\data\rl\2\9PA\131019_0.htm 17.08.2011
Removing and installing pistons Page 3 of 9
Component overview
Identification of pistons
Note
Piston marking
Pistons are installed as standard in three dimensional groups: I, X and
II.
These data are all engraved on the piston crown. To uniquely identify a piston, it must be carefully cleaned
(brass brush, ultrasonic bath). If, in spite of very thorough cleaning, the data are unreadable, the piston must
be weighed together with piston rings, piston pin and the two circlips. Thorough cleaning (ultrasonic bath) is
also absolutely essential to the weighing operation as otherwise the measurement result will be false.
1. A piston removed for repair is cleaned and identified. If it needs to be replaced, an X - piston with the
identified weight tolerance + or - is ordered as a replacement part and installed.
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Removing and installing pistons Page 4 of 9
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
3. Remove chain case cover. → 153121 21 Removing chain case cover - section on "Removing"
Removing pistons
Removing pistons
Note
Connecting rod bolts and bearing shells must always be
replaced.
2. Remove one piston after another, mark them and place them on
Holding bridges at bearings 3 and 5
a clean tray. The arrow on the bottom of the piston points in the
direction of travel.
5. Press the piston downwards out of the cylinder, for example with the handle of a hammer, and receive it
with the other hand.
6. Fit the connecting-rod bearing cap again immediately on the big end of the connecting-rod bearing with
the bearing shells and place the entire piston on a clean surface.
7. Mark piston with No. 1 (with a felt-tip, not with a prick punch or other sharp-edged tool).
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Removing and installing pistons Page 5 of 9
Note
Note the association between the connecting-rod big end and the
connecting-rod bearing cap as the cracked connecting rods only
fit in one position.
Note
Note the association between the connecting-rod big end and the
connecting-rod bearing cap as the cracked connecting rods only
fit in one position.
Installing pistons
Installing pistons
Note
Connecting rod bolts and bearing shells must always be replaced.
The identification of the connecting-rod bearings is located on the connecting-rod journal of the
crankshaft → Removing and installing crankshaft.
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Removing and installing pistons Page 6 of 9
Note
The pistons must already be pre-fitted (pistons, piston rings, connecting rods and fastening material)
before performing the next step. → 131037 Disassembling and assembling pistons - chapter on
"assembling"
Install with the number on the connecting rod -A- to the exhaust side.
When installing the piston in the crankcase, the direction of travel arrow on the piston crown must point in
the direction of travel.
Allocation
The direction of travel arrow must be pointing forwards when
installed (in direction of travel).
1. Turn the engine in the engine support so that the crankshaft lies
at the bottom.
Installing pistons
2. Install piston. To do this, turn the crankshaft with a wrench (a/f 27) until the corresponding crank pin is
pointing vertically downwards.
3. Cylinder, piston and Piston ring restraining strap for 944 - S2 and Boxster and 911 Carrera (996)
NR.57 leicht einölen.
4. Align piston-ring set (staggered by 120°) and compress piston rings using piston ring restraining strap
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Removing and installing pistons Page 7 of 9
for 944 - S2 and Boxster and 911 Carrera (996) NR.57. Ensure all piston rings are correctly pre-loaded
by the special tool -see figure- .
5. Position piston on the cylinder from above and push it into the
cylinder, using the handle of a hammer if necessary. When doing
so, make sure that the direction of travel arrow is pointing
forwards -see arrow (illustration shows cylinder 1)- .
Installing pistons
6. Push piston downwards until the connecting-rod bearing sits on
the crank pin. If necessary, use the handle of a hammer to push
it -see figure- .
Note
The piston connecting rods are cracked and only fit in one
position (in conjunction with the matching numbers).
Pressing in piston
Install con-rod code towards exhaust side -A- .
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Removing and installing pistons Page 8 of 9
12. Tighten con-rod bolts that have been replaced. Turn the
crankshaft until the corresponding crank pin is pointing vertically
upwards. Tighten bolts with a multiple-tooth socket → Initial
tightening 1: 6 ftlb. → Initial tightening 2: 15 ftlb. → Initial
tightening 3: 30 ftlb. → Torque angle (final tightening): 90 ° .
View of matching numbers -A-
13. Once all pistons have been correctly fitted and secured, turn the
crankshaft in a clockwise direction to check it, using a ring
wrench (a/f 27). When doing so, watch out for stiffness and
irregularities. If the crankshaft cannot be turned or if it is very stiff,
check whether the installation direction (arrow) of the pistons, the
pistons and the cylinders (markings) and the connecting-rod cap
and connecting-rod big end all match.
Subsequent work
2. Install chain case cover. → 153123 23 Installing chain case cover - section on "Installing"
3. Install oil pan → 175023 Oil pan installed (including seal) - section on "Installing"
5. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
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Removing and installing pistons Page 9 of 9
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\131019_0.htm 17.08.2011
Disassembling and assembling pistons Page 2 of 11
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Disassembling and assembling pistons Page 3 of 11
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Disassembling and assembling pistons Page 4 of 11
Preliminary work
Piston disassembly
Tools
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Disassembling and assembling pistons Page 5 of 11
-C- Assembly sleeve → "See Workshop For fitting the piston pin
9500/9 Equipment Manual, circlip in the correct position
Chapter 2.2.2"
-D- Plunger 9500/8 → "See Workshop For fitting the piston pin and
Equipment Manual, piston pin circlip
Chapter 2.2.2"
-E- Piston ring pliers 58 → "See Workshop
Equipment Manual,
Chapter 2.4"
Information
Component overview
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Disassembling and assembling pistons Page 6 of 11
Identification of pistons
Note
Piston marking
Pistons are installed as standard in three dimensional groups: I, X and
II.
These data are all engraved on the piston crown. To uniquely identify a piston, it must be carefully cleaned
(brass brush, ultrasonic bath). If, in spite of very thorough cleaning, the data are unreadable, the piston must
be weighed together with piston rings, piston pin and the two circlips. Thorough cleaning (ultrasonic bath) is
also absolutely essential to the weighing operation as otherwise the measurement result will be false.
1. A piston removed for repair is cleaned and identified. If it needs to be replaced, an X - piston with the
identified weight tolerance + or - is ordered as a replacement part and installed.
Disassembling pistons
Disassembling pistons
Note
If reusing a piston, do not remove combustion residues on the piston crown are mechanically!
Note
When disassembling the piston/connecting rod unit, note or mark the position, relationship to cylinder
and installation position using a waterproof felt tip pen.
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Disassembling and assembling pistons Page 7 of 11
ATTENTION
Engine damage if piston rings overstretched!
→ Do not overstretch piston rings with piston ring pliers. Spread the
piston ring until it just fits over the piston.
Piston pin with plunger
5. Remove piston rings. Place the piston on a clean surface and look for the gaps in the piston rings.
Note
Compression rings and oil scraper rings are installed and
removed differently.
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Disassembling and assembling pistons Page 8 of 11
8. Remove the three-piece oil scraper ring as follows: First, remove the upper and lower rings by hand by
carefully forcing them away from the piston. Then remove the oil scraper spring carefully in the same
way.
Assembling pistons
Assembling pistons
1. First assemble the three-piece oil scraper ring. To do this, carefully stretch the oil scraper spring by hand
at its gap to a point where this can be positioned over the piston in ring groove 3. Carefully force apart a
ring in the oil scraper ring by hand and fit it into the third piston ring groove below the oil scraper spring.
Fit the second ring in the same way over the oil scraper spring.
2. When fitted, the gap in the oil scraper ring must be offset by exactly 180° with respect to the gap in the
oil scraper spring. Make sure that the oil scraper spring is in the middle of the oil scraper ring.
Note
The two compression rings have different strengths and can only
be installed in the appropriate groove.
If the piston ring has the inscription TOP, this must point to the
piston crown.
3. Insert piston ring into the piston ring pliers. Make sure that, when
installed, the designation of the piston rings is pointing in the
direction of the piston crown -A- . Spread the piston ring until it
just fits over the piston. Piston ring designation
4. Fit piston rings. Using the piston ring pliers, insert the middle piston ring into the second ring groove in
such a way that the inscription TOP is facing the piston crown. Insert the top piston ring into ring groove
1 in such a way that the inscription TOP is facing the piston crown.
5. Check that the piston rings are correctly seated and positioned. Make sure that the oil scraper spring is
inside the oil scraper ring. In the case of the piston ring in ring groove 2, the inscription TOP must point
to the piston crown. The top piston ring must be installed in such a way that the inscription TOP is facing
the piston crown. The gaps in the individual piston rings must always be offset by 120°.
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Disassembling and assembling pistons Page 9 of 11
8. Check installation position of piston-pin circlip in the assembly sleeve → Ring gap here at 6 o'clock .
Allocation
13. Fit oiled piston pin through the piston and connecting-rod eye as far as the circlip. Using a plastic
hammer, tap gently on plunger 9500/8, driving the piston pin into the pre-fitted piston-pin circlip -arrow- .
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Disassembling and assembling pistons Page 10 of 11
14. Fit the second piston-pin circlip using the same procedure. Align gap of circlip so that it points
downwards away from the piston crown (analogous to 6 o'clock, alternatively 11 o'clock) -arrow- .
15. Check connecting rod and piston for smooth operation.
Note
The connecting rods are cracked and together with the matching
numbers cannot be mixed up!
Subsequent work
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Disassembling and assembling pistons Page 11 of 11
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\131037_0.htm 17.08.2011
Removing and installing crankshaft Page 2 of 15
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
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Removing and installing crankshaft Page 3 of 15
3. Remove oil pan. → 175019 21 Removing and installing oil pan - section on "Removing"
4. Remove oil pump. → 172019 Removing and installing oil pump - section on "Removing"
Removing crankshaft
Removing crankshaft
1 - Crankshaft
2 - Straight pin
3 - Feather key
4 - Thrust washer, insert with grease no. 000.043.204.17
5 - Upper crankshaft bearing shell, lubricate with motor oil
6 - Lower crankshaft bearing shell, lubricate with motor oil
7 - Radial shaft sealing ring, crankshaft
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Removing and installing crankshaft Page 4 of 15
Note
The colour codes of the crankshaft bearings and bearing shells must match!
To ensure that the bearings and bearing shells are of a matching class during installation, the bearing
numbers are to be written on the backs of the bearings during removal of the main bearing shells with a
waterproof felt-tipped pen, due to that fact that the ink markings wear off of the crankshaft journals as
well as the main bearing shells.
New bearing shells are always to be installed when the engine is repaired.
Crankshaft
Main bearing shells Red yellow Blue
+ connecting-rod
bearing shells Red X
yellow X
Blue X
3. Unscrew the outer cross bolt connection (M8 x 70) in the opposite order to the sequence shown.
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Clutch side
4. The figures below indicate the tightening sequence. The fastening screws are undone in the opposite
order to the tightening sequence shown.. → Outer bearing seat
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5. Undo inner bearing seat in the opposite order to the tightening sequence shown. → Inner bearing seat
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7. Remove any remaining sealant and the old sealing ring in the upper part of the crankcase.
ATTENTION
Danger of crushing!
Risk of crushing your hands when lifting the crankshaft.
10. Undo holding bridges 9677 and carefully remove crankshaft upwards.
Installing crankshaft
Installing crankshaft
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Note
If no clear markings can be seen after thorough cleaning of the crankshaft and the bearings, the
crankshaft and the corresponding bearing shells are to be replaced.
Note
The bearing shells are available in various tolerance classes. The
classes are indicated by the colour marking on the outside
-refer to Figure- . The colour marking must match the
corresponding colour dot on the crankshaft. The colours are red,
yellow and blue and must match between the bearings and the
crankshaft.
New connecting rod bearings main bearing shells are always to be installed when the motor is repaired.
1. Insert the bearing shells with the lubricating groove into the upper part of the crankcase. Make sure the
twist locks are positioned correctly -see figure- . Then lightly oil the bearing locations.
ATTENTION
Danger of crushing!
Risk of crushing your hands when lifting the crankshaft.
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7. Make sure the crankcase is ready to be screwed in. Check that the sickle discs are positioned correctly.
Degrease parting surfaces between top and bottom section of crankcase. A totally grease-free product
(e.g. brake cleaner) must be used for this. Then insert a new O-ring at the front of the parting surface -3-
.
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8. Screw the two thin centring pins 9321 into the outer fastening bores on the upper part of the crankcase
-see illustration (shown without crankshaft)- .
9. Insert bearing shells into lower part of crankcase and lightly oil them. When doing so, ensure that the
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Centring pins
twist locks (retaining lugs) fit into the appropriate recesses in the lower part of the crankcase.
Note
The liquid sealant must be applied and the screws screwed in within five minutes at most and without
interruption.
The required tool (torque wrench for 15 Nm (11 ftlb.) to 40 Nm (30 ftlb.); torque angle wrench; socket
wrench E12, E14 and E14) must be ready for use.
The threads and head contact surface of the bearing seat screws (M10 x 1.5 and M12 x 1.5) must be
oiled.
10. Apply the Drei Bond Silikon 2210 liquid sealant to the lower part of the crankcase as illustrated. The
outer surfaces marked -A- must be cleaned after fitting.
Sealant application
11. Place bottom section of crankcase into position. When doing so, make sure that the sealing bead is not
destroyed.
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Note
Unscrew the centring pins again while securing the lower part of the crankcase.
12. The figures below indicate the tightening sequence. The screws are tightened in four steps. It is essential
that the tightening sequence is observed here. The screws must be tightened within five minutes.
→ Final tightening: 56 °
→ Final tightening: 60 °
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13. Then screw on the outer cross bolt connection (M8 x 70) in the sequence shown → Tightening torque:
17 ftlb. .
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14. Tighten the four hexagon socket bolts on the clutch side (M8 x
35) → Tightening torque: 17 ftlb. .
Clutch side
15. Fit chain drive sprocket on the crankshaft. Unscrew fastening screw on belt pulley. Check that the
feather keys are fitted correctly and push on the chain sprocket with the oil pump drive chain → Chain
drive wheel . The double-tooth row must be facing forwards.
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Subsequent work
2. Install oil pan. → 175019 23 Removing and installing oil pan - section on "Installing"
4. Install chain case lid. → 153123 23 Installing chain case lid - section on "Installing"
5. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\134819_0.htm 17.08.2011
Removing and installing crankshaft sealing ring on flywheel side Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Removing and installing crankshaft sealing ring on flywheel side Page 3 of 6
Preliminary work
Preliminary work
1. Remove drive plate or flywheel. → 136019 Removing and installing flywheel [9PAAE7]→ 136019
Removing and installing flywheel [9PAAE1 9PAAF1 9PAAJ1] or → 136319 Removing and installing drive
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Removing and installing crankshaft sealing ring on flywheel side Page 4 of 6
plate for torque converter [9PAAE1 9PAAF1 9PAAJ1]→ 136319 Removing and installing drive plate for
torque converter [9PAAE7]
Required tools
1. Using the tool drift punch (1-mm tip) NR.167, beat a small hole into a non-rubberised spot (rectangular
window in the ring) of the sealing ring.
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2. Screw in the extractor tip. Knock out the extractor tip using slide hammer kit NR.168 in conjunction with
the sealing ring.
ATTENTION
Damage to the sealing ring!
2. Position the centring device on the crankshaft flange. Pay attention to the centring pin when doing this.
Tighten the two fastening screws to 23 Nm (17 ftlb.).
3. Position the retracting bell and tighten the central screw (a/f 19) to 25 Nm (19 ftlb.).
5. Undo the two fastening screws on the centring device and remove the tool.
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Fitting bell
Subsequent work
Subsequent work
1. Install drive plate or flywheel. → 136019 Removing and installing flywheel [9PAAE7]→ 136019 Removing
and installing flywheel [9PAAE1 9PAAF1 9PAAJ1] or → 136319 Removing and installing drive plate for
torque converter [9PAAE1 9PAAF1 9PAAJ1]→ 136319 Removing and installing drive plate for torque
converter [9PAAE7]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\135919_1.htm 17.08.2011
Removing and installing drive plate for torque converter Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
file://C:\POSES\data\rl\2\9PA\136319_1.htm 17.08.2011
Removing and installing drive plate for torque converter Page 3 of 5
Preliminary work
Preliminary work
1. Remove transmission. → 373519 Removing and installing transmission - chapter on
"Removing" [9PAAJ1]→ 373519 Removing and installing transmission - chapter on "Removing" [9PAAE1
9PAAF1]
Special tools
Puller
file://C:\POSES\data\rl\2\9PA\136319_1.htm 17.08.2011
Removing and installing drive plate for torque converter Page 4 of 5
Toothed segment
2. Unscrew drive plate. To do this, loosen the ten diagonally
opposite fastening screws.
Drive plate
5. To do this, insert internal puller into the middle of the drive plate
and tighten.
Internal puller
6. Then screw on the slide hammer and knock off the drive plate.
file://C:\POSES\data\rl\2\9PA\136319_1.htm 17.08.2011
Removing and installing drive plate for torque converter Page 5 of 5
Note
Clean the crankshaft stub before installing the drive plate
(remove rust).
Slide hammer
2. Block drive plate. To do this, attach toothed segment 95381 to a
screw hole in the crankcase so that at least one tooth is in
contact with the starter teeth.
Toothed segment
3. Tighten the ten new fastening screws crosswise. → Tightening
torque: 44 ftlb. ; then → Torque angle: 90 °
Fastening screws
Subsequent work
Subsequent work
1. Install transmission. → 373519 Removing and installing transmission - chapter on "Installing" [9PAAJ1]
→ 373519 Removing and installing transmission - chapter on "Installing" [9PAAE1 9PAAF1]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\136319_1.htm 17.08.2011
Removing and installing belt tensioner Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Loosen drive belt around the belt tensioner. → 137819 Removing and installing drive belt - chapter on
"Removing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing drive belt - chapter on
"Removing" [9PAAE1 9PAAE7]
Information
Component overview
file://C:\POSES\data\rl\2\9PA\137319_1.htm 17.08.2011
Removing and installing belt tensioner Page 3 of 5
1 - Deflection roller, cylinder bank 1-4 → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
2 - Tensioning roller
3 - Holder for deflection roller
4 - Fastening screw for damper → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
5 - Support for tensioning roller → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
6 - Shock absorber/tensioning element; bellows must be facing upwards. Observe code on the component.
7 - Deflection roller, cylinder bank 5-8 → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
8 - Sheetmetal holder
file://C:\POSES\data\rl\2\9PA\137319_1.htm 17.08.2011
Removing and installing belt tensioner Page 4 of 5
Deflection roller
Note
When fitting the shock absorber/tensioning element, ensure that the label can be read from outside.
Subsequent work
Subsequent work
1. Fit drive belt. → 137819 Removing and installing drive belt - chapter on "Installing" [9PAAF1 9PAAJ1]
→ 137819 Removing and installing drive belt - chapter on "Installing" [9PAAE1 9PAAE7]
file://C:\POSES\data\rl\2\9PA\137319_1.htm 17.08.2011
Removing and installing belt tensioner Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\137319_1.htm 17.08.2011
Removing and installing sealing ring for crankshaft belt pulley Page 2 of 4
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Component overview
-1- - Radial shaft seal (align using the plastic sleeve provided)
-2- - Upper fastening screw
-3- - Lower fastening screw
-4- - Chain tensioner
Preliminary work
file://C:\POSES\data\rl\2\9PA\137419_0.htm 17.08.2011
Removing and installing sealing ring for crankshaft belt pulley Page 3 of 4
Preliminary work for removing sealing ring for crankshaft sealing ring
1. Remove pulley (vibration balancer) of the crankshaft → 137619 Removing and reinstalling crankshaft belt
pulley - chapter on "Removing".
1. Undo the 4 fastening screws and remove the cover and sealing
ring.
2. Clean the sealing surface of the sheetmetal cover.
WARNING
Risk of damaging the sealing ring due to assembly fault!
Never pull the sealing ring from the plastic sleeve!
Do not touch the sealing lip!
Do not oil the sealing ring on the running surface!
Note
If the joint flange on the pulley or the surface on the crankshaft stub is slightly rusted, polish the rust off
with a special polishing pad.
2. Tighten the 2 upper fastening screws by hand → Tightening torque: 7.5 ftlb. , and then the lower
fastening screws → Tightening torque: 7.5 ftlb. . Then tighten the screws in diagonally opposite
sequence to the specified torque.
file://C:\POSES\data\rl\2\9PA\137419_0.htm 17.08.2011
Removing and installing sealing ring for crankshaft belt pulley Page 4 of 4
Plastic sleeve
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\137419_0.htm 17.08.2011
Removing and installing crankshaft belt pulley Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
file://C:\POSES\data\rl\2\9PA\137619_0.htm 17.08.2011
Removing and installing crankshaft belt pulley Page 3 of 6
Preliminary work
2. Loosen drive belt and remove from the pulley. For details see → 137819 Removing and reinstalling drive
belt - chapter on "Removing" [9PAAF1 9PAAJ1]→ 137819 Removing and reinstalling drive belt - chapter
on "Removing" [9PAAE1 9PAAE7].
1. Position arm bracket 96790 in the pulley and turn it until it locks.
ATTENTION
Material damage!
If the tool slips or if the tool is faulty, the wings or the
cooling fan can be damaged as a result of excessive forces!
2. Position a large torque wrench and loosen the central screw. Do not use the screw again.
3. Remove the central screw and pull the pulley down and forward.
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Removing and installing crankshaft belt pulley Page 4 of 6
Installing crankshaft
belt pulley
Note
A key is inserted into the crankshaft. When fitting the pulley,
ensure that the key lies in the groove in the pulley.
1. Position the pulley on the crankshaft stub. Then press the pulley
slightly in the direction of the engine, while at the same time
twisting it until it slips definitively in the direction of the timing- Pulley on crankshaft stub
case cover. When doing so, pay attention to the key.
2. Mount the new central screw hand tight into the crankshaft.
ATTENTION
Material damage!
If the tool slips or if the tool is faulty, the wings or the
cooling fan can be damaged as a result of excessive forces!
file://C:\POSES\data\rl\2\9PA\137619_0.htm 17.08.2011
Removing and installing crankshaft belt pulley Page 5 of 6
3. Position arm bracket 96790 in the pulley and turn it until it locks. Have a second worker operate the arm
bracket.
ATTENTION
Material damage!
If the tool slips or if the tool is faulty, the wings or the
cooling fan can be damaged as a result of excessive forces!
4. Tighten central screw. → Initial tightening: 20 (15 ftlb.) Nm , then → Initial tightening: 50 (37 ftlb.)
Nm , then → Initial tightening: 250 (185 ftlb.) Nm
ATTENTION
Material damage!
If the tool slips or if the tool is faulty, the wings or the
cooling fan can be damaged as a result of excessive forces!
Subsequent work
file://C:\POSES\data\rl\2\9PA\137619_0.htm 17.08.2011
Removing and installing crankshaft belt pulley Page 6 of 6
Drive belt
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\137619_0.htm 17.08.2011
Checking drive belt Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped
pipe) [9PAAF1 9PAAJ1]→ 243519 Removing and installing cowl for throttle part (Y-shaped
pipe) [9PAAE1 9PAAE7]
Information
Information
ATTENTION
Risk of damage to drive belt!
If the drive belt is removed when it is hot, it may become deformed and damaged.
ATTENTION
Consequential damage of broken pulley belt!
Due to a broken drive belt during driving, surrounding components (panelling, electric cables
etc.) can be damaged by thrashing or flying belt parts.
Parts of the drive belt can jam behind deflection rollers or vibration balancers and damage
surfaces and sealing rings there. In particular, the sealing ring of the crankshaft vibration
balancer can become leaky as a result of a broken belt.
→ Following a belt breakage the surrounding components and the interior of the engine compartment must
be inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration
balancer, deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.
The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration
file://C:\POSES\data\rl\2\9PA\137801_0.htm 17.08.2011
Checking drive belt Page 3 of 5
WARNING
Danger of injury!
The vehicle fans can continue running or start up automatically.
→ The power supply to the radiator fans or the battery must be disconnected before starting to work on the
radiator or fans (remove fuse → fuse carrier [9PAAJ1]→ fuse carrier [9PAAE1 9PAAE7 9PAAF1]).→
Work instructions after disconnecting the battery
Damage symptoms
Note
The following table indicates damage which necessitates replacement.
file://C:\POSES\data\rl\2\9PA\137801_0.htm 17.08.2011
Checking drive belt Page 4 of 5
Note
If spark plugs must be changed in the course of maintenance operations, the drive belt should be
checked when the spark plugs are removed. The engine can then be cranked easier.
1. Using chalk, mark the drive belt in the area around the tensioning roller.
2. Turn engine at the vibration damper in the direction of movement using a socket wrench (a/f 27) until the
chalk mark is at the same place again. While turning at the crankshaft, check the belt at the deflection
rollers for signs of damage.
Subsequent work
file://C:\POSES\data\rl\2\9PA\137801_0.htm 17.08.2011
Checking drive belt Page 5 of 5
Subsequent work
1. Fit intake manifold (cowl). → 243519 Removing and installing
cowl for throttle part (Y-shaped pipe) [9PAAF1 9PAAJ1]→ 243519
Removing and installing cowl for throttle part (Y-shaped
pipe) [9PAAE1 9PAAE7]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\137801_0.htm 17.08.2011
Removing and installing drive belt Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped pipe)
Information
Information
ATTENTION
Risk of damage to drive belt!
If the drive belt is removed when it is hot, it may become deformed and damaged.
ATTENTION
Consequential damage of broken pulley belt!
Due to a broken drive belt during driving, surrounding components (panelling, electric cables
etc.) can be damaged by thrashing or flying belt parts.
Parts of the drive belt can jam behind deflection rollers or vibration balancers and damage
surfaces and sealing rings there. In particular, the sealing ring of the crankshaft vibration
balancer can become leaky as a result of a broken belt.
→ Following a belt breakage the surrounding components and the interior of the engine compartment must
be inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration
balancer, deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.
→ The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration
balancers for prior damage.
file://C:\POSES\data\rl\2\9PA\137819_2.htm 17.08.2011
Removing and installing drive belt Page 3 of 6
WARNING
Danger of injury!
The vehicle fans can continue running or start up automatically.
→ The power supply to the radiator fans or the battery must be disconnected before starting to work on the
radiator or fans (remove fuse → fuse carrier).→ Work instructions after disconnecting the battery
file://C:\POSES\data\rl\2\9PA\137819_2.htm 17.08.2011
Removing and installing drive belt Page 4 of 6
Note
The figure → Drive belt threading course shows the complete belt
threading course. The pulleys are numbered according to the
sequence of fitting.
1. Make the belt into a loop and place over the crankshaft belt pulley behind the dipstick.
2. Place the top part of the belt loop over the coolant pump pulley -1- .
file://C:\POSES\data\rl\2\9PA\137819_2.htm 17.08.2011
Removing and installing drive belt Page 5 of 6
Deflector wheel
5. Then guide the section of the belt around the air-conditioning
compressor belt pulley -4- at the bottom.
Air-conditioning compressor
6. Lay a loop around the power-steering pump -5- .
7. Lay the loose end of the drive belt from the coolant pump downwards and around the generator pulley
-6- and deflector roller -7- of cylinder bank 1 - 4.
8. Gather the belt section between the deflection roller of cylinder bank 1 - 4 and the crankshaft pulley to
form a loop and guide it upwards to the tensioning roller -8- . Use a wrench (a/f 30) to turn the tensioning
file://C:\POSES\data\rl\2\9PA\137819_2.htm 17.08.2011
Removing and installing drive belt Page 6 of 6
Tensioning roller
roller -8- in a clockwise direction at the hexagon and put on the drive belt. Slowly relieve the tensioning
roller.
Subsequent work
Subsequent work
1. Fit intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped pipe)
9PAAE1, 9PAAE7
as of MY 2003
Country C20, C21, C22, C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45,
C46, C98, C99
file://C:\POSES\data\rl\2\9PA\137819_2.htm 17.08.2011
Removing camshaft housing Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove intake-air distributor. → 244601 Checking intake-air distributor for leaks - section on "Removing"
7. Remove cover for camshaft housing . → 159121 Removing cover for camshaft housing - section on
file://C:\POSES\data\rl\2\9PA\150321_0.htm 17.08.2011
Removing camshaft housing Page 3 of 6
"Removing"
10. Remove flat-base tappets and put down in accordance with installation position. → Removing and
installing flat-base tappets
1- Camshaft housing
2- Camshaft sensor fastening screw M6 x 16
3- Camshaft sensor
4- Plug
5- Cheese head bolt M8 x 20
6- Cheese head bolt M8 x 30
7- Sealant application on camshaft housing. Make sure that no sealant can fall into the cylinder head.
Carefully remove old residual sealing compound.
file://C:\POSES\data\rl\2\9PA\150321_0.htm 17.08.2011
Removing camshaft housing Page 4 of 6
1. Unscrew the upper fastening screw -3- of oil line. Replace sealing ring -2- .
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Removing camshaft housing Page 5 of 6
Note
When removing the camshaft housing, ensure that none of the
sealing rings or residual sealant fall into the cylinder head.
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Removing camshaft housing Page 6 of 6
file://C:\POSES\data\rl\2\9PA\150321_0.htm 17.08.2011
Removing camshaft housing Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove intake-air distributor. → 244601 Checking intake-air distributor for leaks - section on "Removing"
7. Remove cover for camshaft housing . → 159121 Removing cover for camshaft housing - section on
"Removing"
file://C:\POSES\data\rl\2\9PA\150321_1.htm 17.08.2011
Removing camshaft housing Page 3 of 6
10. Remove flat-base tappets and put down in accordance with installation position. → Removing and
installing flat-base tappets
1- Camshaft housing
2- Camshaft sensor fastening screw M6 x 16
3- Camshaft sensor
4- Plug
5- Cheese head bolt M8 x 20
6- Cheese head bolt M8 x 30
7- Sealant application on camshaft housing. Make sure that no sealant can fall into the cylinder head.
Carefully remove old residual sealing compound.
8 - Camshaft housing securing screw M8 x 45
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Removing camshaft housing Page 4 of 6
9 - Sealant application on spark plug recess. Make sure that no sealant can fall into the cylinder head.
Carefully remove old residual sealing compound.
10 - Oil duct sealing ring
Oil strainer
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Removing camshaft housing Page 5 of 6
Note
When removing the camshaft housing, ensure that none of the
sealing rings or residual sealant fall into the cylinder head.
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Removing camshaft housing Page 6 of 6
as of MY 2005
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\150321_1.htm 17.08.2011
Installing camshaft housing Page 2 of 7
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
file://C:\POSES\data\rl\2\9PA\150323_0.htm 17.08.2011
Installing camshaft housing Page 3 of 7
1- Camshaft housing
2- Camshaft sensor fastening screw M6 x 16
3- Camshaft sensor
4- Plug
5- Cheese head bolt M8 x 20
6- Cheese head bolt M8 x 30
7- Sealant application on camshaft housing. Make sure that no sealant can fall into the cylinder head.
Carefully remove old residual sealing compound.
8 - Camshaft housing securing screw M8 x 45
9 - Sealant application on spark plug recess. Make sure that no sealant can fall into the cylinder head.
Carefully remove old residual sealing compound.
10 - Oil duct sealing ring
Note
Before installing, remove all residual sealing compound and clean sealing surfaces on cylinder head and
camshaft housing!
1. Clean sealing surfaces on camshaft housing and cylinder head using suitable means (e.g. acetone and
cloth).
Note
The sealant application must not be too thick because otherwise excess sealant can enter the cylinder
head!
For applying the sealant, there are, amongst other things, two grooves on the front section of the
camshaft housing!
2. Replace oil duct sealing ring on cylinder head and apply a thin bead (approximate width 1.5 mm) of
sealing compound (000 043 300 39, status 12/05) onto the camshaft housing in accordance with
-Illustration- . When doing this, do not forget the sealing surfaces of the spark plug recesses.
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Installing camshaft housing Page 4 of 7
3. Place camshaft housing on cylinder head. Position M8 fastening screws and tighten in tightening
sequence → Tightening sequence for camshaft housing . → Tightening torque: 23 (17 ftlb.) Nm
4. Tighten hexagon socket head bolts in control box -Arrows- as required → Tightening torque: 23 (17
ftlb.) Nm (on cylinder row 1-4 the screws are located on the side, on the outside of the chain box). Wipe
off excess silicone as far as control box.
5. Secure oil line with new sealing ring -2- . To do this, screw down the upper fastening screw -3- of oil line.
→ Tightening torque: 10 (7.5 ftlb.) Nm
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Installing camshaft housing Page 5 of 7
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Installing camshaft housing Page 6 of 7
Subsequent work
Subsequent work
Ground connection
4. Secure oil feed line by hand in the camshaft housing with the
union nut and then tighten. → Tightening torque: 35 (26 ftlb.)
Nm
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Installing camshaft housing Page 7 of 7
8. Install cover for camshaft housing . → 159123 Installing cover for camshaft housing - section on
"Installing"
9. Install intake-air distributor. → 244619 Removing and installing intake-air distributor - section on
"Installing"
10. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
file://C:\POSES\data\rl\2\9PA\150323_0.htm 17.08.2011
Installing camshaft housing Page 2 of 7
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
file://C:\POSES\data\rl\2\9PA\150323_1.htm 17.08.2011
Installing camshaft housing Page 3 of 7
1- Camshaft housing
2- Camshaft sensor fastening screw M6 x 16
3- Camshaft sensor
4- Plug
5- Cheese head bolt M8 x 20
6- Cheese head bolt M8 x 30
7- Sealant application on camshaft housing. Make sure that no sealant can fall into the cylinder head.
Carefully remove old residual sealing compound.
8 - Camshaft housing fastening screw M8 x 45
9 - Sealant application on spark plug recess. Make sure that no sealant can fall into the cylinder head.
Carefully remove old residual sealing compound.
10 - Oil duct sealing ring
Note
Before installing, remove all residual sealing compound and clean sealing surfaces on cylinder head and
camshaft housing!
1. Clean sealing surfaces on camshaft housing and cylinder head using suitable means (e.g. acetone and
cloth).
Note
The sealant application must not be too thick because otherwise excess sealant can enter the cylinder
head!
For applying the sealant, there are, amongst other things, two grooves on the front section of the
camshaft housing!
2. Replace oil duct sealing ring on cylinder head and apply a thin bead (approximate width 1.5 mm) of liquid
sealing compound 000.043.300.39 Loctite 5970 (status 11/2005, for details of currently used sealant,
see Spare Parts Catalogue) onto the camshaft housing in accordance with -Illustration- . When doing
this, do not forget the sealing surfaces of the spark plug recesses.
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Installing camshaft housing Page 4 of 7
3. Place camshaft housing on cylinder head. Position M8 fastening screws and tighten according to
specified tightening sequence → Tightening sequence for camshaft housing . → Tightening torque: 23
(17 ftlb.) Nm
4. Tighten hexagon socket head bolts in control box -Arrows- as required → Tightening torque: 23 (17
ftlb.) Nm (screws are located on the side, on the outside of the chain box, on cylinder row 1 - 4). Wipe
off excess silicone as far as timing case.
5. An oil strainer is fitted under the camshaft adjustment valve in the camshaft housing. Check oil strainer
and clean in solvent naphtha or replace if necessary. Fit oil strainer into the bore on the camshaft
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Installing camshaft housing Page 5 of 7
housing -1- . The oil strainer prevents dirt from getting into the camshaft adjustment valve. → Oil strainer
Oil strainer
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Installing camshaft housing Page 6 of 7
Subsequent work
Subsequent work
1. Turbocharged engine (M48/50): Screw down sheetmetal bracket for turbocharger. To do this, tighten the
2 fastening screws → Tightening torque: 23 (17 ftlb.) Nm and screw with new nut → Tightening
torque: 30 (22 ftlb.) Nm . → Sheetmetal bracket for turbocharger
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Installing camshaft housing Page 7 of 7
Ground connection
4. Secure oil feed line by hand in the camshaft housing with the
union nut and then tighten. → Tightening torque: 35 (26 ftlb.)
Nm
8. Install cover for camshaft housing . → 159123 Installing cover for camshaft housing - section on
"Installing"
9. Install intake-air distributor. → 244619 Removing and installing intake-air distributor - section on
"Installing"
10. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2005
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\150323_1.htm 17.08.2011
Checking timing of camshafts Page 2 of 2
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Information
Note
Checking the timing is not possible for the M48/00 and M48/50 engines. Only an adjustment can be
made→ 150516 Adjusting timing for camshafts.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\150502_1.htm 17.08.2011
Adjusting the timings for the camshafts Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Adjusting the timings for the camshafts Page 3 of 6
Preliminary work
Preliminary work
Note
To remove the play from the timing chain for the setting process, the crankshaft must be positioned at
least 45° in front of the TDC of cylinder 1 before turning!
1. Remove camshaft housing cover on both cylinder rows → 159121 Removing camshaft housing cover -
Chapter "Removing".
ATTENTION
Damage to engine by turning crankshaft against the rotation
direction of the engine (engine assembled)!
Note
The setting is always checked simultaneously on both cylinder rows. Once a cylinder row has been set,
the crankshaft must not be turned to set the other cylinder row!
The fastening screws on the sprocket wheels do not need to be replaced after they have been undone.
The screws on the sprocket wheels are tightened by hand during assembly and are then loosened by
one or two turns. This play is necessary so that the camshafts can still be turned.
The setting is carried out with the standard chain tensioner that is installed.
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Adjusting the timings for the camshafts Page 4 of 6
2. Use socket wrench insert 9714 to turn crankshaft until cylinder 1 is in ignition TDC. Insert fixing pins
9595/1 into the relevant groove in the timing chain housing cover through the bore provided in the
crankshaft gearwheel -see figure- .
Note
If the cams on cylinder 1 are not positioned as shown, check
whether the crankshaft needs to be turned through another turn
(360°)!
Cams of cylinder 1
Special tools
Tools
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Adjusting the timings for the camshafts Page 5 of 6
The crankshaft is positioned in the TDC and is fixed using fixing pins 9595/1 once the above preliminary
check has been performed.
Note
The fastening screws on the sprocket wheels do not need to be
replaced after they have been undone.
1. Undo all four fastening screws of the camshaft wheels (two camshaft adjusters) on both cylinder rows.
For this purpose, hold the hexagon of the camshaft wheel on the respective camshaft with the ring
wrench and release pan-head screw M12 1 by 2 revolutions
--To illustrate the process more clearly, the figure does not show the timing case lid-- .
Note
Cylinder rows 1 - 4 and 5 - 8 are adjusted at the same time
without the camshaft being turned!
Hexagon on camshaft
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Note
Cylinder rows 1 - 4 and 5 -
8 are adjusted at the same
time without the camshaft
being turned!
Subsequent work
Reworking
1. Install camshaft housing cover on both cylinder rows → 159123 Installing camshaft housing cover -
Chapter "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\150516_0.htm 17.08.2011
Removing camshafts Page 2 of 4
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
2. Remove camshaft adjusters. For details, refer to → 158419 Removing and installing camshaft adjusters -
"Removing" chapter.
3. Remove camshaft timing gears. For details, see → 150719 Removing and installing camshaft timing gear
- chapter on "Removing".
Removing camshafts
Removing camshafts
Note
While removing, note the installation position and allocation of the camshafts and bearing caps on a
sheet of paper in such a way that they cannot be mixed up.
Protect camshafts, bearing caps and camshaft housing from dirt and layout the components on a clean
surface according to installation position.
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Position of camshafts
1. Unscrew fastening screws M6 x 16 of the inlet camshaft oil feed housing and pull it off to the front.
Note
While removing, note the installation position and allocation of the camshafts and bearing caps on a
sheet of paper in such a way that they cannot be mixed up.
Protect camshafts, bearing caps and camshaft housing from dirt and layout the components on a clean
surface according to installation position.
Note
When releasing the camshaft bearing caps, all the fastening screws must be released evenly half a turn
at a time in the reverse order to that illustrated so that the camshaft is not distorted!
2. Remove all the M6 x 35 fastening screws of the thrust bearing cap and bearing caps evenly half a turn at
a time in the reverse order to that illustrated -see figure- . Layout thrust bearing and bearing caps on a
clean surface according to installation position.
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Removing camshafts Page 2 of 4
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
2. Remove camshaft adjusters. For details, refer to → 158419 Removing and installing camshaft adjusters -
"Removing" chapter.
3. Remove camshaft timing gears. For details, see → 150719 Removing and installing camshaft timing gear
- chapter on "Removing".
Removing camshafts
Removing camshafts
Note
While removing, note the installation position and allocation of the camshafts and bearing caps on a
sheet of paper in such a way that they cannot be mixed up.
Protect camshafts, bearing caps and camshaft housing from dirt and layout the components on a clean
surface according to installation position.
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Removing camshafts Page 3 of 4
Position of camshafts
1. Unscrew fastening screws (M6 x 16) of the inlet camshaft oil feed housing and pull it off to the front.
Note
While removing, note the installation position and allocation of the camshafts and bearing caps on a
sheet of paper in such a way that they cannot be mixed up.
Protect camshafts, bearing caps and camshaft housing from dirt and layout the components on a clean
surface according to installation position.
Note
When releasing the camshaft bearing caps, all the fastening screws must be released evenly half a turn
at a time in the reverse order to that illustrated so that the camshaft is not distorted!
Note
As of model year 2005, the first camshaft bearing cap has two
standard bores for securing the hydraulic valve (two M6 x 60
screws) -1- . An additional oil strainer is fitted under the hydraulic
valve.
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Removing camshafts Page 4 of 4
3. Remove camshafts and lay out on a clean surface according to installation position.
as of MY 2005
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\150521_1.htm 17.08.2011
Installing camshafts Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Installing camshafts
Installing camshafts
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Installing camshafts Page 3 of 5
Note
Ensure the bearing caps are correctly positioned and allocated.
Note
Place the camshafts in such a way that the cams are positioned as shown below!
Note
The camshafts of the turbocharged engine have a blue colour identification, the camshafts of the naturally
aspirated engine a white colour identification.
3. Place camshafts as shown in the -illustration- . When doing so, pay particular attention to the relative
position of the cams to each other.
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Installing camshafts Page 4 of 5
4. Place oiled bearing caps on camshaft bearings. The matching number of the bearing caps must
correspond to the camshaft housing. For each cylinder, the bearing caps are numbered consecutively
from the front (timing chain side) -B- . The designation of the bearing cap and matching number can be
read from the exhaust side -A- .
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Installing camshafts Page 5 of 5
B - Bearing cap A/3-2 Bearing cap consecutive numbering exhaust between cylinders 3 and 2 etc.
B - Bearing cap E/1 Bearing cap consecutive numbering inlet cylinder 1 etc
5. Fit bearing cap. The tightening sequence must be strictly observed → Tightening torque: 7.5 ftlb.
-tightening sequence- .
6. Fit oil feed housing of inlet camshaft. To do this, slide the well-oiled oil feed housing over the plain
compression rings of the camshaft → Tightening torque: 7.5 ftlb. .
Subsequent work
1. Install camshaft adjusters. For details, refer to → 158419 Removing and installing camshaft adjusters -
"Installing" chapter.
2. Install camshaft timing gears. For details see → 150719 Removing and installing camshaft timing gear -
chapter on "installing".
3. Install camshaft housing cover → 159123 Removing and installing cover for camshaft housing - chapter
on "installing".
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Installing camshafts Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Installing camshafts
Installing camshafts
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Installing camshafts Page 3 of 6
Note
Ensure the bearing caps are correctly positioned and allocated.
Note
Place the camshafts in such a way that the cams are positioned as shown below!
Note
The camshafts of the turbocharged engine have a blue colour identification, the camshafts of the naturally
aspirated engine a white colour identification.
3. Place camshafts as shown in -Illustration- . When doing so, pay particular attention to the way the cams
are positioned in relation to each other.
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Installing camshafts Page 4 of 6
4. Put oiled bearing caps onto the camshaft bearings. The matching number of the bearing caps must
correspond to the camshaft housing. For each cylinder, the bearing caps are numbered consecutively
from the front (timing chain side) -B- . The designation of the bearing cap and matching number can be
read from the exhaust side -A- .
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B - Bearing cap A/3-2 Bearing cap consecutive numbering exhaust between cylinders 3 and 2 etc.
B - Bearing cap E/1 Bearing cap consecutive numbering inlet cylinder 1 etc
Note
As of model year 2005, the first camshaft bearing cap has two
standard bores for securing the hydraulic valve (two M6 x 60
screws) -1- . An additional oil strainer is fitted under the hydraulic
valve.
6. Fit oil feed housing of inlet camshaft. To do this, slide the well-oiled oil feed housing over the plain
compression rings of the camshaft → Tightening torque: 10 (7.5 ftlb.) Nm .
Subsequent work
1. Install camshaft adjusters. For details, refer to → 158419 Removing and installing camshaft adjusters -
"Installing" chapter.
2. Install camshaft timing gears. For details see → 150719 Removing and installing camshaft timing gear -
chapter on "installing".
3. Install camshaft housing cover → 159123 Removing and installing cover for camshaft housing - chapter
on "installing".
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Installing camshafts Page 6 of 6
as of MY 2005
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\150523_1.htm 17.08.2011
Removing and installing camshaft timing gear Page 2 of 7
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Removing and installing camshaft timing gear Page 3 of 7
Preliminary work
Special tools
Tools
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camshafts
-C- Locating pin 9595/1 → "See Workshop For fixing the pulley. The
Equipment Manual, piston of cylinder 1 is then at
Chapter 2.2.2 " TDC; position locating pin
correctly in groove provided
in timing case.
ATTENTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine
assembled)!
→ Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing
chain jumps over).
→ Proceed carefully while working as otherwise the engine can be damaged.
→ Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
→ After working on the camshaft wheels, the timing must be set.
→ Please observe the general warning notes and working regulations → 1001AW The most important
working regulations and warning notes
1. Using socket 9714, turn the crankshaft until cylinder 1 is located at ignition TDC.
Note
If the cams on cylinder 1 are not positioned as shown, check
whether the crankshaft still needs to be turned through another
turn (360°)!
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Note
The fastening screws of the sprockets must be replaced after removal.
The diamond washers of the chain sprockets must be replaced after removal.
The screws of the sprocket wheels are tightened by hand during assembly and are then loosened by one
or two turns. This play is necessary so that the camshafts can still be turned.
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6. Just loosen the fastening screw of the camshaft adjuster (1 or 2 turns). To do this, counter the a/f 32
hexagon of the camshaft adjuster and camshaft timing gear with a ring wrench. Only remove the cheese
head bolt of the camshaft timing gear
-to illustrate the operation more clearly, the figure does not include the timing case cover-- .
7. If necessary, use a rubber hammer to carefully loosen the camshaft timing gear from the back.
ATTENTION
Engine damage due to small parts falling into the timing case (e.g. diamond washer)!
→ Do not let the diamond washer under the camshaft timing gear and camshaft adjuster fall into the timing
case.
Note
There is a diamond washer between the camshaft and camshaft timing gear and between the camshaft
and camshaft adjuster. This is to be replaced after the corresponding wheel has been removed. If the
fastening screw of the wheel is only loosened to adjust the timing (1 or 2 revolutions), the diamond
washer does not need to be replaced.
8. Use both hands, to carefully remove the camshaft timing gear from the chain.
ATTENTION
Engine damage due to small parts falling into the timing case
(e.g. diamond washer)!
→ Do not let the diamond washer under the camshaft timing gear
and camshaft adjuster fall into the timing case.
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Note
If they have been removed, replace the diamond washer and M12 cheese head screw of the camshaft.
2. Lift the timing chain and carefully place the camshaft timing gear
on the camshaft. To get sufficient play in the timing chain, it may
be necessary to turn the loosened camshaft adjuster back and
forth. Place timing chain on camshaft timing gear.
Subsequent work
2. Install camshaft housing cover. → 159123 Removing and installing cover for camshaft housing - chapter
on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\150719_0.htm 17.08.2011
Removing chain case lid Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Separate engine from transmission and suspend it on the assembly support using engine support 9676.
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5. Loosen (do not remove) the three fastening screws on the water pump pulley.
Drive belt
Information
Component overview
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Removing chain case lid Page 4 of 8
Installation location
Component overview
Note
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Removing chain case lid Page 5 of 8
The description only explains how to remove the chain case lid. The removal of other components is
described in the corresponding chapters.
1. Remove the belt tensioner. To do this, loosen the fastening screws -4 and 5- on the carrier and on the
underside of the shock absorber.
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Removing chain case lid Page 6 of 8
Note
To ensure that the used
fastening screw of the
crankshaft belt pulley is
not used again, mark it
with a felt-tip pen.
Cable duct
7. Disconnect coolant line to the generator.
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10. Remove crankshaft sealing ring on timing case cover. To do this, loosen the four fastening screws.
ATTENTION
Risk of engine leaks!
When dismantling the timing-case cover, the sealing bead between the oil pan and crankcase can
become damaged.
→ When dismantling the timing-case cover, the oil pan has to be resealed every time.
11. Remove timing-case cover. To do this, loosen all the fastening screws in reverse order (beginning with
position 28).
12. Remove oil pan. → 175021 Oil pan removed - chapter on "Removing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
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Removing chain case lid Page 8 of 8
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Installing chain case lid Page 2 of 12
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Component overview
Installation location
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Component overview
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
Note
Acetone can be used to clean the sealing faces. Ventilate this for 5 minutes before applying more
sealant.
1. Clean and degrease the sealing faces of the engine and housing lid.
2. Attach the four seals -1, 2, 3 and 4- to the chain case lid.
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Lid seals
3. Apply a bead of liquid sealant 000.043.300.39 Loctite 5970 (status 11/2005, for details of currently used
sealant, see Parts Catalogue) to the contact points of the camshaft housing/cylinder head, cylinder
head/crankcase and crankcase upper section/crankcase lower section. The bead of sealant should
protrude about 20 mm over the contact points. → Sealant application
Sealant application
Note
In the case of the M48/50 (turbo) engine, sealant must also be applied to the metal seal in the chain
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tensioner area.
Sealant application
4. Screw down all fastening screws by hand. At this stage, the screw heads should not be all the way down.
Note
The chain case lid must be aligned using a dial gauge or steel gauge.
The chain case lid must not project over the lower section of the crankcase.
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1 - M6 x 25 screw
2 - M6 x 50 screw
3 - M8 x 50 screw
5. Push the chain case lid upwards slightly and tighten the fastening screws -7, 8, 9 and 10- (about 1 - 2
Nm (0.5 - 1.5 ftlb.) in such a way that the lid is slightly jammed. Then align the lid. → 153123 15 Installing
chain case lid - section on "Adjusting"
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Installing chain case lid Page 7 of 12
Tightening sequence
ATTENTION
Danger of leaks!
If the chain case lid is not aligned properly, this component
or the oil pan may start to leak during operation.
→ The chain case lid must not project over the crankcase.
→ It cannot go under 0.1 mm (dimension A = 0.1 mm).
1. Insert the dial gauge into the universal gauge holder and position Adjusting the preload
it in such a way that the dial gauge has a preload of about 1 mm.
2. Set dial gauge scale to 0. To do this, place the dial gauge holder
on a completely flat surface (e.g. crankcase flange) and turn the
dial gauge scale until the pointer is at 0.
4. Align the chain case lid by tapping lightly with a rubber hammer.
file://C:\POSES\data\rl\2\9PA\153323_1.htm 17.08.2011
Installing chain case lid Page 8 of 12
Note
See figure! → Tightening sequence
The quality of the exterior fastening screws must be 10.9. Checking the position
Tightening sequence
file://C:\POSES\data\rl\2\9PA\153323_1.htm 17.08.2011
Installing chain case lid Page 9 of 12
Tightening sequence
Subsequent work
Subsequent work
1. Install oil pan. → 175023 Oil pan installed (includes sealing)
2. Install engine carrier. → 103519 Removing and installing engine mount - section on "Installing"
file://C:\POSES\data\rl\2\9PA\153323_1.htm 17.08.2011
Installing chain case lid Page 10 of 12
Fastening screws
6. Fit deflection roller of cylinder row 1 - 4. → Tightening torque: 32 (24 ftlb.) Nm Then clip on cap.
7. Tighten coolant pump pulley. → 195019 Removing and installing coolant pump pulley - section on
"Installing"
file://C:\POSES\data\rl\2\9PA\153323_1.htm 17.08.2011
Installing chain case lid Page 11 of 12
Belt tensioner
9. Fit and tension the drive belt. → 137819 Removing and installing
drive belt [9PAAF1 9PAAJ1]→ 137819 Removing and installing
drive belt [9PAAE1 9PAAE7]
Drive belt
10. Install chain tensioner with new sealing ring. → 153619 Removing and installing chain tensioner - section
on "Installing"
11. Install oil dipstick. → 171719 Removing and installing guide for oil dipstick - section on "Installing"
12. Check timing and adjust if necessary. → 150516 Setting the timing
file://C:\POSES\data\rl\2\9PA\153323_1.htm 17.08.2011
Installing chain case lid Page 12 of 12
13. Install cover for camshaft housing (valve cover). → 159123 Installing cover for camshaft housing
14. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\153323_1.htm 17.08.2011
Removing timing chain Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
ATTENTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine
assembled)!
→ Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing
chain jumps over).
→ Proceed carefully while working as otherwise the engine can be damaged.
→ Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
→ After working on the camshaft wheels, the timing must be set.
→ Please observe the general warning notes and working regulations → 1001AW The most important
working regulations and warning notes
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove cover for camshaft housing. → 159121 Removing cover for camshaft housing
Information
Component overview
file://C:\POSES\data\rl\2\9PA\153521_0.htm 17.08.2011
Removing timing chain Page 3 of 5
file://C:\POSES\data\rl\2\9PA\153521_0.htm 17.08.2011
Removing timing chain Page 4 of 5
Note
If the timing chain has to be removed or replaced, check the guide and tensioning rails for wear and scoring
and replace them if necessary.
file://C:\POSES\data\rl\2\9PA\153521_0.htm 17.08.2011
Removing timing chain Page 5 of 5
Note
The rolling direction of the timing chain must always be the same.
2. Pull guide rails between the camshafts away from the threaded
pegs. To do this, let timing chain dangle between the camshafts.
Note
If the timing chain is to be reused, the rolling direction of the
timing chain must be marked before it is removed.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\153521_0.htm 17.08.2011
Fitting timing chain Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Component overview
file://C:\POSES\data\rl\2\9PA\153523_0.htm 17.08.2011
Fitting timing chain Page 3 of 5
ATTENTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine
assembled)!
file://C:\POSES\data\rl\2\9PA\153523_0.htm 17.08.2011
Fitting timing chain Page 4 of 5
→ Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing
chain jumps over).
→ Proceed carefully while working as otherwise the engine can be damaged.
→ Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
→ After working on the camshaft wheels, the timing must be set.
→ Please observe the general warning notes and working regulations → 1001AW The most important
working regulations and warning notes
Note
The rolling direction of the timing chain must always be the same.
If the timing chain is to be reused, the rolling direction of the timing chain must be marked before it is
removed.
Note
If the timing chain has to be removed or replaced, check the guide and tensioning rails for wear and scoring
and replace them if necessary.
Camshaft timing gears and camshaft adjusters must be installed and it must be possible to turn them.
1. Place timing chain loosely on all sprockets. Ensure that the timing chain is in the correct position on the
guide rails.
2. Fit guide and tensioning rails. For details, see → Removing and installing guide and tensioning rails
Subsequent work
Subsequent work
file://C:\POSES\data\rl\2\9PA\153523_0.htm 17.08.2011
Fitting timing chain Page 5 of 5
3. Install cover for camshaft housing. → 159123 Installing cylinder head cover
4. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\153523_0.htm 17.08.2011
Removing and installing chain tensioner Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Component overview
ATTENTION
Risk of damage to timing drive mechanism!
Never twist the crankshaft against the direction of rotation.
file://C:\POSES\data\rl\2\9PA\153619_0.htm 17.08.2011
Removing and installing chain tensioner Page 3 of 5
Remove and install the chain tensioner only in overlapping TDC. (The chain tensioner is under
the least amount of pressure in this position).
Never twist the crankshaft when the chain tensioner is removed.
→ Forces from the valve drive can cause the timing chain to jump over or tilt.
Note
All spark plugs (except for those on cylinder 3) must be removed to ensure that the relevant dead centre
can be found more easily.
Note
An alternative method for determining the overlapping TDC is the
"cylinder pipe" (dead centre finder). This tool is part of the pressure-
loss tester WE 1066, Workshop Installation Manual 3.1.4.
file://C:\POSES\data\rl\2\9PA\153619_0.htm 17.08.2011
Removing and installing chain tensioner Page 4 of 5
3. Open cable clip -7- of the generator's electric cable and press the cable upwards.
Note
If the chain tensioner is removed, the aluminium sealing ring must be replaced.
file://C:\POSES\data\rl\2\9PA\153619_0.htm 17.08.2011
Removing and installing chain tensioner Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\153619_0.htm 17.08.2011
Removing and installing hydraulic valve for camshaft adjustment Page 2 of 4
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove cover for camshaft housing → 159121 Removing and installing cover for camshaft housing -
section on "Removing".
Note
The hydraulic valve for camshaft adjustment as of model year 2005 does not fit on the bearing cap and
camshaft housing of model years 2003 to 2004.
file://C:\POSES\data\rl\2\9PA\153719_0.htm 17.08.2011
Removing and installing hydraulic valve for camshaft adjustment Page 3 of 4
If an engine of model years 2003 to 2004 is to be converted to suit a new hydraulic valve with oil strainer,
the camshaft housing and all camshaft bearing caps must be replaced.
Note
The hydraulic valve for camshaft adjustment as of model year 2005 does not fit on the bearing cap and
camshaft housing of model years 2003 to 2004.
If an engine of model years 2003 to 2004 is to be converted to suit a new hydraulic valve with oil strainer,
the camshaft housing and all camshaft bearing caps must be replaced.
file://C:\POSES\data\rl\2\9PA\153719_0.htm 17.08.2011
Removing and installing hydraulic valve for camshaft adjustment Page 4 of 4
3. Screw in fastening screw -Arrow- and tighten. → Tightening torque: 10 (7.5 ftlb.) Nm
Subsequent work
Subsequent work
1. Install cover for camshaft housing → 159123 Removing and installing cover for camshaft housing -
section on "Installing".
file://C:\POSES\data\rl\2\9PA\153719_0.htm 17.08.2011
Removing and installing hydraulic valve for camshaft adjustment Page 2 of 4
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove cover for camshaft housing → 159121 Removing and installing cover for camshaft housing -
section on "Removing".
Note
The hydraulic valve for camshaft adjustment as of model year 2005 does not fit on the bearing cap and
camshaft housing of model years 2003 to 2004.
If an engine of model years 2003 to 2004 is to be converted to suit a new hydraulic valve with oil strainer,
the camshaft housing and all camshaft bearing caps must be replaced.
file://C:\POSES\data\rl\2\9PA\153719_1.htm 17.08.2011
Removing and installing hydraulic valve for camshaft adjustment Page 3 of 4
2. Remove oil strainer with a small magnet. If the oil strainer cannot
be removed through the housing, the bearing cap must be
removed.
Note
The hydraulic valve for camshaft adjustment as of model year 2005 does not fit on the bearing cap and
camshaft housing of model years 2003 to 2004.
If an engine of model years 2003 to 2004 is to be converted to suit a new hydraulic valve with oil strainer,
the camshaft housing and all camshaft bearing caps must be replaced.
1. Insert the oil strainer into the camshaft housing under the first
camshaft bearing cap. You do not have to remove the camshaft
bearing cap to do this (Figure shows oil strainer without camshaft
bearing cap → Oil strainer partly inserted in camshaft housing ).
file://C:\POSES\data\rl\2\9PA\153719_1.htm 17.08.2011
Removing and installing hydraulic valve for camshaft adjustment Page 4 of 4
Subsequent work
Subsequent work
1. Install cover for camshaft housing → 159123 Removing and installing cover for camshaft housing -
section on "Installing".
as of MY 2005
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\153719_1.htm 17.08.2011
Removing and installing guide and tensioning rails Page 2 of 12
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove cover for camshaft housing . → 159121 Removing cover for camshaft housing - section on
"Removing"
3. Remove chain case lid. → 153121 21 Removing chain case lid - section on "Removing"
4. Mark rolling direction of timing chain. Remove timing chain from all chain sprockets, pulling it forwards.
→ 153521 Removing timing chain - section on "Removing"
Information
Component overview
file://C:\POSES\data\rl\2\9PA\154719_0.htm 17.08.2011
Removing and installing guide and tensioning rails Page 3 of 12
file://C:\POSES\data\rl\2\9PA\154719_0.htm 17.08.2011
Removing and installing guide and tensioning rails Page 4 of 12
Component overview 1
file://C:\POSES\data\rl\2\9PA\154719_0.htm 17.08.2011
Removing and installing guide and tensioning rails Page 5 of 12
Component overview 2
1 - Tensioning rail
2 - Threaded pegs
3 - Guide rails
4 - Threaded pegs
5 - Chain tensioner M24 x 1.5; replace sealing ring
6 - Guide rail
Note
If the timing chain has to be removed or replaced, check the guide and tensioning rails for wear and scoring
and replace them if necessary.
file://C:\POSES\data\rl\2\9PA\154719_0.htm 17.08.2011
Removing and installing guide and tensioning rails Page 6 of 12
Note
The rolling direction of the timing chain must always be the same.
If the timing chain is to be reused, the rolling direction of the timing chain must be marked before it is
removed.
Note
If the timing chain is to be reused, the rolling direction of the timing chain must be marked before it is
removed.
1. Remove top guide rails -6- if this has not yet been done. Pull guide rail -3- and tensioning rail -1- off
threaded pegs. Ensure that the spring of the tensioning rail for the oil pump drive is in the correct position
in relation to the guide rail -3- .
2. Remove guide rail -3- by loosening four fastening screws (M8 x 35).
file://C:\POSES\data\rl\2\9PA\154719_0.htm 17.08.2011
Removing and installing guide and tensioning rails Page 7 of 12
Guide rail
3. Remove plastic lid of oil pump drive -7- . To do this, unscrew two M5 x 20 screws -8- and remove plastic
lid. Remove guide rail -9- and tensioning rail -6- .
file://C:\POSES\data\rl\2\9PA\154719_0.htm 17.08.2011
Removing and installing guide and tensioning rails Page 8 of 12
file://C:\POSES\data\rl\2\9PA\154719_0.htm 17.08.2011
Removing and installing guide and tensioning rails Page 9 of 12
2. Fit guide rail -3- . To do this, screw in four fastening screws (M8 x 35). → Tightening torque: 24 ftlb.
file://C:\POSES\data\rl\2\9PA\154719_0.htm 17.08.2011
Removing and installing guide and tensioning rails Page 10 of 12
Guide rail
3. Attach guide rail -3- and tensioning rail -1- to threaded pegs. Position the spring of the tensioning rail for
oil pump drive correctly on guide rail -3- . Fit top guide rails -6- when installing the timing chains.
file://C:\POSES\data\rl\2\9PA\154719_0.htm 17.08.2011
Removing and installing guide and tensioning rails Page 11 of 12
Subsequent work
Subsequent work
1. Install timing chain. → 153523 Installing timing chain - section on "Installing"
2. Install chain case lid. → 153123 23 Installing chain case lid - section on "Installing"
3. Set the timing. → 150516 Adjusting timing for camshafts - section on "Adjusting"
4. Install cover for camshaft housing . → 159123 Installing cover for camshaft housing - section on
"Installing"
5. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
file://C:\POSES\data\rl\2\9PA\154719_0.htm 17.08.2011
Removing and installing guide and tensioning rails Page 12 of 12
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\154719_0.htm 17.08.2011
Removing and installing hydro-tappets Page 2 of 3
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove camshafts . → 150521 Remove camshafts - Chapter "Removing"
Removing hydro-tappets
Removing hydro-tappets
Note
If the flat-base tappets are to be reused, they must be marked
according to installation position using a water-resistant felt-tip
pen and stored in such a way that they cannot be mixed up!
1. Pull the flat-base tappets out of the camshaft housing one after
the other and store them in such a way that they cannot be mixed
up. Pulling flat-base tappets out of the
camshaft housing
E - Intake side
A - Exhaust side
5 bis 8 - Cylinders
Installing hydro-tappets
Installing hydro-tappets
file://C:\POSES\data\rl\2\9PA\155919_0.htm 17.08.2011
Removing and installing hydro-tappets Page 3 of 3
Subsequent work
Subsequent work
1. Install camshafts . → 150523 Install camshafts - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\155919_0.htm 17.08.2011
Removing and installing intake valve Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove cylinder head. → 157021 Removing cylinder head
3. Take flat-base tappets out of the cylinder head and lay them on a clean surface, arranged according to
cylinders and valves. → 155955 21 Removing and installing flat-base tappets - chapter on "Removing" .
Do not interchange components.
Information
Component overview
file://C:\POSES\data\rl\2\9PA\156019_0.htm 17.08.2011
Removing and installing intake valve Page 3 of 8
In the Turbo, the exhaust valve is fitted with internal and external valve springs and adapted concave
washers (different to those shown in the figure below). The exhaust valve in the turbo engine has the
same dimensions as the exhaust valve in the naturally aspirated engine; because of the sodium filling
it is lighter however and when obtained as a spare part it features a coloured dot to distinguish it. For
further details, please see later chapter entitled "Valve dimensions".
file://C:\POSES\data\rl\2\9PA\156019_0.htm 17.08.2011
Removing and installing intake valve Page 4 of 8
Note
Secure the cylinder head on a level surface, which allows easy access to the valves from underneath.
The cylinder head fastening must not tip over when tools are used.
Note
The illustrations show part of the cylinder head installed.
1. The spark plugs must be removed and the valve lock screwed in
before the valves are removed → Screwing in tool . The valve
lock prevents the valves from being opened while being pressed
down. Alternatively, a rubber plate placed underneath helps if the
cylinder head surface is smooth -2- .
Screwing in tool
Locking valves
2. Fit and adjust lever tool from the valve key
assembly/disassembly tool for the Cayenne NR.54-1 set on
the cylinder head. When doing so, ensure that the middle pipe is
positioned centrally over the spark-plug recesses. The operating
lever can be secured centrally or excentrically. The fastening
screws in the camshaft bearing caps in the front and rear bearing
position are used to secure the tool brackets → Removing tool
setup for valve springs (figure shows fitted cylinder head). Use
the white plastic pressure piece with the magnetic insert to
remove the valve keys. The assembly must be performed as
shown → Removing tool setup for valve springs .
file://C:\POSES\data\rl\2\9PA\156019_0.htm 17.08.2011
Removing and installing intake valve Page 5 of 8
Locking valves
Note
Intake valves come in different sizes to exhaust valves. It is impossible to mix them up. Intake valves are
identical in the naturally aspirated and turbo engines.
Exhaust valves in the turbo engine weigh less than exhaust valves in the naturally aspirated engine.
They are marked with a green dot. Do not interchange them.
The valves can be grinded using commercially available valve grinding paste.
2. Oil the valve stem of a new valve and insert it into the valve guide from the combustion chamber. Push
the valve in until it is seated securely in the valve seat of the cylinder head.
3. Grind in the valve using the commercially available valve grinding tool (with rubber suction cup) by
means of rotary movements. To do this, hold the valve grinder between the palms of both hands and
press against the valve seat with rotating movements → Grinding the valve seat .
file://C:\POSES\data\rl\2\9PA\156019_0.htm 17.08.2011
Removing and installing intake valve Page 6 of 8
ATTENTION
Valve grinding paste residues can cause mechanical damage!
4. Carry out the grinding operation for each valve that is replaced.
Check for leaks using some fuel and installed spark plugs. The
fuel must not escape through the valve seat. Carefully remove
valve grinding paste.
Locking valves
7. Fit valve springs, concave washer and valve keys. To do this,
place valve springs (there are two in the exhaust valve in the
turbo engine) on the bottom concave washer. Place top concave
washer in position. Pull off the ring of the assembly tool -2- from
the retaining springs -3- before inserting the valve keys. Position
valve keys with the thin side facing upwards -1- .
file://C:\POSES\data\rl\2\9PA\156019_0.htm 17.08.2011
Removing and installing intake valve Page 7 of 8
Subsequent work
Subsequent work
1. Fit flat-based tappets. Do not interchange components. → 155955 23 Removing and reinstalling flat-base
tappet - chapter on "Installing"
Information
Valve dimensions
file://C:\POSES\data\rl\2\9PA\156019_0.htm 17.08.2011
Removing and installing intake valve Page 8 of 8
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\156019_0.htm 17.08.2011
Removing and installing exhaust valve Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove cylinder head. → 157021 Removing cylinder head
3. Take flat-base tappets out of the cylinder head and lay them on a clean surface, arranged according to
cylinders and valves. → 155955 21 Removing and installing flat-base tappets - chapter on "Removing" .
Do not interchange components.
Information
Component overview
file://C:\POSES\data\rl\2\9PA\156219_0.htm 17.08.2011
Removing and installing exhaust valve Page 3 of 8
In the Turbo, the exhaust valve is fitted with internal and external valve springs and adapted concave
washers (different to those shown in the figure below). The exhaust valve in the turbo engine has the
same dimensions as the exhaust valve in the naturally aspirated engine; because of the sodium filling
it is lighter however and when obtained as a spare part it features a coloured dot to distinguish it. For
further details, please see later chapter entitled "Valve dimensions".
file://C:\POSES\data\rl\2\9PA\156219_0.htm 17.08.2011
Removing and installing exhaust valve Page 4 of 8
Note
Secure the cylinder head on a level surface, which allows easy access to the valves from underneath.
The cylinder head fastening must not tip over when tools are used.
Note
The illustrations show part of the cylinder head installed.
1. The spark plugs must be removed and the valve lock screwed in
before the valves are removed → Screwing in tool . The valve
lock prevents the valves from being opened while being pressed
down. Alternatively, a rubber plate placed underneath helps if the
cylinder head surface is smooth -2- .
Screwing in tool
Locking valves
2. Fit and adjust lever tool from the valve key
assembly/disassembly tool for the Cayenne NR.54-1 set on
the cylinder head. When doing so, ensure that the middle pipe is
positioned centrally over the spark-plug recesses. The operating
lever can be secured centrally or excentrically. The fastening
screws in the camshaft bearing caps in the front and rear bearing
position are used to secure the tool brackets → Removing tool
setup for valve springs (figure shows fitted cylinder head). Use
the white plastic pressure piece with the magnetic insert to
remove the valve keys. The assembly must be performed as
shown → Removing tool setup for valve springs .
file://C:\POSES\data\rl\2\9PA\156219_0.htm 17.08.2011
Removing and installing exhaust valve Page 5 of 8
Locking valves
Note
Intake valves come in different sizes to exhaust valves. It is impossible to mix them up. Intake valves are
identical in the naturally aspirated and turbo engines.
Exhaust valves in the turbo engine weigh less than exhaust valves in the naturally aspirated engine.
They are marked with a green dot. Do not interchange them.
The valves can be grinded using commercially available valve grinding paste.
2. Oil the valve stem of a new valve and insert it into the valve guide from the combustion chamber. Push
the valve in until it is seated securely in the valve seat of the cylinder head.
3. Grind in the valve using the commercially available valve grinding tool (with rubber suction cup) by
means of rotary movements. To do this, hold the valve grinder between the palms of both hands and
press against the valve seat with rotating movements → Grinding the valve seat .
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ATTENTION
Valve grinding paste residues can cause mechanical damage!
4. Carry out the grinding operation for each valve that is replaced.
Check for leaks using some fuel and installed spark plugs. The
fuel must not escape through the valve seat. Carefully remove
valve grinding paste.
Locking valves
7. Fit valve springs, concave washer and valve keys. To do this,
place valve springs (there are two in the exhaust valve in the
turbo engine) on the bottom concave washer. Place top concave
washer in position. Pull off the ring of the assembly tool -2- from
the retaining springs -3- before inserting the valve keys. Position
valve keys with the thin side facing upwards -1- .
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Removing and installing exhaust valve Page 7 of 8
Subsequent work
Subsequent work
1. Fit flat-based tappets. Do not interchange components. → 155955 23 Removing and reinstalling flat-base
tappet - chapter on "Installing"
Information
Valve dimensions
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Removing and installing exhaust valve Page 8 of 8
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing valve-stem seal Page 2 of 10
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Removing and installing valve-stem seal Page 3 of 10
Preliminary work
Preliminary work
Note
The cylinder head can remain fitted while this work is carried out.
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
3. Take flat-base tappets out of the cylinder head and lay them on a clean surface, arranged according to
cylinders and valves. → 155955 21 Removing and installing flat-base tappets - section on "Removing" .
Do not interchange components.
Information
Component overview
In the Turbo, the exhaust valve is fitted with internal and external valve springs and adapted concave
washers (different to those shown in the figure below). The exhaust valve in the turbo engine has the
same dimensions as the exhaust valve in the naturally aspirated engine; because of the sodium filling
it is lighter however and when obtained as a spare part it features a coloured dot to distinguish it. For
further details, please see later chapter entitled "Valve dimensions".
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Note
When required, all valve-stem seals on both cylinder rows must be replaced.
Note
Before switching to another cylinder, the cylinder must be positioned at the bottom dead centre and
supplied with compressed air (see above).
Note
Position the pistons of the relevant cylinder at the bottom dead centre.
1. Set piston for the corresponding cylinder to bottom dead centre. To do this, guide the timing chain
carefully when turning the crankshaft.
2. Screw in compressed-air hose from the valve key assembly/disassembly tool for the Cayenne
NR.54-1 tool set in the relevant spark plug bore so that it is tightly sealed. Apply compressed air
constantly to cylinder (at least 6 bar overpressure). This builds up the pressure in the cylinder so that
the valve does not fall into the cylinder while the work is being carried out. Replace all four valve-
stem seals for a cylinder and refit valve keys. Only then fit compressed-air hose on the next cylinder and
apply compressed air constantly.
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Closed puller
6. When engaging the puller 3364, push sliding sleeve down and close tool. -arrow-
Note
Position the pistons of the relevant cylinder at the bottom dead centre.
Note
Before switching to another cylinder, the cylinder must be positioned at the bottom dead centre and
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Removing and installing valve-stem seal Page 7 of 10
Note
When required, all valve-stem seals on both cylinder rows must be replaced.
Note
Protective caps must be ordered as separate spare parts. They are reusable. They are used to protect the
valve-stem seal so that it is not damaged at the valve stem end.
Protective cap
3. Oil valve stem, protective cap and valve-stem seal. Push valve-
stem seal with sealing lip upwards -1- over the protective cap -2-
onto the valve stem. Remove protective cap.
5. Fit valve springs, concave washer and valve keys. To do this, place valve springs (there are two in the
exhaust valve in the turbo engine) on the bottom concave washer. Place top concave washer in position.
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Pull off the ring of the assembly tool -2- from the retaining springs -3- before inserting the valve keys.
Position valve keys with the thin side facing upwards -1- .
6. Insert valve keys into the assembly tool with the thin side facing
upwards -1- . Ensure that the valve keys fit symmetrically and are
inserted as far as they will go in the assembly tool. The retaining
springs are free -2- .
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Removing and installing valve-stem seal Page 9 of 10
10. Replace all four valve-stem seals for a cylinder and refit valve keys. Only then fit compressed-air hose on
the next cylinder and apply compressed air constantly.
Subsequent work
Subsequent work
1. Fit flat-based tappets. → 155955 23 Removing and installing flat-base tappets - section on "Installing" .
Do not interchange components.
3. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
Information
Valve dimensions
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Removing and installing valve-stem seal Page 10 of 10
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\156319_0.htm 17.08.2011
Removing cylinder head Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Note
If more comprehensive work, e.g. replacement of the entire cylinder head, is intended, the exhaust
manifolds must also be removed. → 261019 Removing and installing exhaust manifold - Chapter
"Removing" [9PAAE1 9PAAE7]→ 261019 Removing and installing exhaust manifold - Chapter
"Removing" [9PAAF1 9PAAJ1]
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove cover for camshaft housing . → 159121 Removing cover for camshaft housing - section on
"Removing"
3. Remove intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - section on
"Removing"
4. Remove chain case lid. → 153121 21 Remove chain case lid – section on "Removing"
Information
Component overview
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Removing cylinder head Page 3 of 6
Component overview
1 - Cap
2 - Cylinder head
3 - Straight pin
4 - Pan-head screw M12 x 1.5 x 140
5 - Cap
6 - Spark plug
7 - Cap
8 - Cylinder-head gasket
9 - Vent connection
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1. Remove guide rail of timing chain -3- . To do this, unscrew fastening screws -4- .
2. Remove oil separator vent line from cylinder head. To do this, unscrew the fastening screws
-3 and upper 4- .
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Removing cylinder head Page 5 of 6
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Note
In the case of the turbocharged engine (M48/50), only the upper
fastening screws of the turbocharger need to be undone.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\157021_0.htm 17.08.2011
Installing cylinder head Page 2 of 9
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Component overview
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Installing cylinder head Page 3 of 9
Component overview
1 - Cap
2 - Cylinder head
3 - Straight pin
4 - Pan-head screw M12 x 1.5 x 140
5 - Cap
6 - Spark plug
7 - Cap
8 - Cylinder-head gasket
9 - Vent connection
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Installing cylinder head Page 4 of 9
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
If components that are cold or at different temperatures are sealed together by the application of
sealant, adhesion problems and leaks can arise due to the build-up of condensation water or
component distortion.
Note
All sealing surfaces must be clean and free of grease!
1. Place cylinder head gasket correctly, i.e. according to the specifications, onto the straight pins of the
engine crank housing. This must be done in such a way that the "Top" marking can be read -figure- .
2. Fit cylinder head. Insert M12 x 1.5 x 140 cylinder head screws (screws can be used again).
3. The tightening sequence 1-10 must be observed for every tightening step.
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Setting torque
→ torque angle: 90 °
Note
In the case of the turbocharged engine (M48/50), screw down the
upper fastening screws of the turbocharger.
6. Place vent line on the cylinder head flange. → Vent line on connection piece of cylinder head To do this,
press the ribbed surfaces of the buttons and pull off the plugs.
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7. Mount oil separator vent line onto cylinder head with new sealing ring -2- . To do this, position and
tighten the fastening screws -3 and upper 4- . → Tightening torque: 7.5 ftlb.
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8. Fasten guide rail of timing chain -3- . To do this, tighten the fastening screws -4- . → Initial tightening:
11 ftlb. → Final tightening: 90 °
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Subsequent work
Subsequent work
1. Install camshaft housing. → 150323 Install camshaft housing – section on "Installing"
2. Install chain case lid. → 153123 23 Install chain case lid – section on "Installing"
3.
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Installing cylinder head Page 9 of 9
Install intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - section on
"Installing"
4. Install cover for camshaft housing . → 159123 Installing cover for camshaft housing - section on
"Installing"
5. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\157023_0.htm 17.08.2011
Replacing attachment for exhaust manifold (stud) Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Note
Only replace studs if they are damaged or their reliability can no longer be assured!
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Replacing attachment for exhaust manifold (stud) Page 3 of 5
Exhaust manifold
1. Screw two M8 nuts onto the stud and counter with two open-
ended wrenches.
Note
Before inserting the new stud, the internal thread in the cylinder head must be checked for damage!
3. Screw in new stud hand-tight, then screw two nuts onto the new stud as before and counter.
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Replacing attachment for exhaust manifold (stud) Page 4 of 5
Dimension A
Engine type Dimension A
M48/00 (naturally aspirated engine) 24.5 - 25.5 mm
M48/50 (turbocharged engine) 23 - 24 mm
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Replacing attachment for exhaust manifold (stud) Page 5 of 5
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\157356_0.htm 17.08.2011
Removing and installing camshaft adjusters Page 2 of 9
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Removing and installing camshaft adjusters Page 3 of 9
Preliminary work
Special tools
Tools
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Removing and installing camshaft adjusters Page 4 of 9
camshafts
-C- Locating pin 9595/1 → "See Workshop For fixing the pulley. The
Equipment Manual, piston of cylinder 1 is then at
Chapter 2.2.2 " TDC; position locating pin
correctly in groove provided
in timing case.
Note
The timing is always set simultaneously on both cylinder banks. Once a cylinder bank has been set, the
crankshaft must not be turned to set the other cylinder bank!
The fastening screws of the chain sprockets must be replaced after removal.
The diamond washers of the chain sprockets must be replaced after removal.
The screws on the sprocket wheels are tightened by hand during assembly and are then loosened by
one or two turns. This play is necessary so that the camshafts can still be turned.
The cylinder bank is set with the standard chain tensioner that is installed.
ATTENTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine
assembled)!
→ Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing
chain jumps over).
→ Proceed carefully while working as otherwise the engine can be damaged.
→ Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
→ After working on the camshaft wheels, the timing must be set.
→ Please observe the general warning notes and working regulations → 1001AW The most important
working regulations and warning notes
1. Using socket 9714, turn the crankshaft until cylinder 1 is located at ignition TDC.
Note
If the cams on cylinder 1 are not positioned as shown, check whether the crankshaft needs to be turned
through another turn (360°)!
2. Make sure that the cams for the 1st cylinder and 5th cylinder are positioned as shown (cylinder 1 at
ignition TDC) -see figure- and → View shows position of cams on cylinder 5 .
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Note
The fastening screw and diamond washer of the camshaft
adjuster only need to be replaced if removed.
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ATTENTION
Engine damage due to small parts falling into the timing case
(e.g. diamond washer)!
→ Do not let the diamond washer under the camshaft timing gear
and camshaft adjuster fall into the timing case.
Note
Take camshaft adjuster out of the
There is a diamond washer between the camshaft and camshaft chain
timing gear or camshaft adjuster. This must be replaced after the
corresponding wheel has been removed. If the fastening screw of the wheel is only loosened in order to
adjust the timing (1 or 2 revolutions), the diamond washer and fastening screw do not need to be
replaced.
8. With both hands, carefully take the camshaft adjuster out of the chain.
9. Remove the diamond washer which is located underneath the camshaft adjuster.
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ATTENTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine
assembled)!
→ Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing
chain jumps over).
→ Proceed carefully while working as otherwise the engine can be damaged.
→ Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
→ After working on the camshaft wheels, the timing must be set.
→ Please observe the general warning notes and working regulations → 1001AW The most important
working regulations and warning notes
Note
If the diamond washer and pan-head screw M12 are removed,
replace the camshaft.
1. Replace the diamond washer and M12 cheese head bolt which
are located underneath the camshaft adjuster.
ATTENTION
Engine damage due to small parts falling into the timing case
(e.g. diamond washer)!
→ Do not let the diamond washer under the camshaft timing gear
and camshaft adjuster fall into the timing case.
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Subsequent work
2. Install camshaft housing cover. → 159123 Removing and installing cover for camshaft housing - chapter
on "installing"
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Removing and installing camshaft adjusters Page 9 of 9
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\158419_0.htm 17.08.2011
Replacing lid seal for camshaft housing (valve lid seal) Page 2 of 2
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Information
1. In order to change the camshaft housing cover seal, the camshaft housing cover must be removed and
installed.→ 159121 Removing camshaft housing cover → 159123 Installing camshaft housing cover
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\159055_0.htm 17.08.2011
Removing cover for camshaft housing Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Removing cover for camshaft housing Page 3 of 8
Preliminary work
Preliminary work
1. Remove engine cover → 108319 Removing and installing engine cover - Chapter "Removing".
2. Remove secondary air pump with console → 266519 Removing and installing secondary air pump -
Chapter "Removing".
3. Remove ignition coils (ignition rod module). Refer to→ 282055 Replacing ignition coils
Special tools
Note
It is best to use a tool that has an head height of less than 50 mm
-A- (see special tools) to loosen and tighten the rear fastening
screw of the cylinder head cover close to the plenum panel.
Tool height
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Information
Component overview
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Removing cover for camshaft housing Page 5 of 8
1 - Design cover
2 - Ball socket
3 - Cover holder
4 - BM8 x 45 screw
5 - Hexagon-head bolt M6 x 40
6 - Engine support bracket
7 - M6 x 30 oval-head screw
8 - Camshaft housing cover on cylinder 1 - 4
9 - Camshaft housing cover seal, inner and outer
10 - Seal for NVS camshaft housing
11 - Cap
12 - Ignition coil (ignition rod module)
13 - Screw with internal thread
14 - Grommet
15 - Sleeve
16 - Countersunk screw, M5 x 16
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Note
The cover for the camshaft housing is removed and installed in the same way on cylinder bank 5 - 8 and
cylinder bank 1 - 4!
Note
Plastic clips can be damaged once the wiring harness holder has
been undone and must be checked to ensure they can be used
again!
ATTENTION
Risk of damage to the position sensor on the camshaft's trigger wheel!
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Removing cover for camshaft housing Page 7 of 8
Note
Wiring harness
If the camshaft housing lid is not removed carefully, it can cause
the trigger wheel on the position sensor at the rear on the camshaft to be bent out of shape!
Note
It is best to use a tool that has an head height of less than 50 mm
-A- (see special tools) to loosen and tighten the rear fastening
screw of the cylinder head cover close to the plenum panel.
6. Turn the camshaft housing lid over and remove inner and outer seal for camshaft housing. Clean sealing
faces on the camshaft housing lid and cylinder head.
Note
Always replace seals.
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Removing cover for camshaft housing Page 8 of 8
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\159121_0.htm 17.08.2011
Installing cover for camshaft housing Page 2 of 10
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
file://C:\POSES\data\rl\2\9PA\159123_0.htm 17.08.2011
Installing cover for camshaft housing Page 3 of 10
Special tools
Note
It is best to use a tool that has an head height of less than 50 mm
-A- (see special tools) to loosen and tighten the rear fastening
screw of the cylinder head cover close to the plenum panel.
Tool height
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Installing cover for camshaft housing Page 4 of 10
Chapter 2.2.2 or
2.2.1"
-B- Torque wrench 90 → "See Workshop
Equipment Manual,
Chapter 2.4"
-C- Socket changeover → "See Workshop
ratchet, 1/4 inch Equipment Manual,
Chapter 2.4"
-D- Socket insert wrench (a/f → "See Workshop
13), 1/4 inch Equipment Manual,
Chapter 2.4"
-E- T40 inner hexagon → "See Workshop
socket bit Equipment Manual,
Chapter 2.4"
Information
Component overview
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Installing cover for camshaft housing Page 5 of 10
1 - Design cover
2 - Ball socket
3 - Cover holder
4 - BM8 x 45 screw
5 - Hexagon-head bolt M6 x 40
6 - Engine support bracket
7 - M6 x 30 oval-head screw
8 - Camshaft housing cover on cylinder 1 - 4
9 - Camshaft housing cover seal, inner and outer
10 - Seal for NVS camshaft housing
11 - Cap
12 - Ignition coil (ignition rod module)
13 - Screw with internal thread
14 - Grommet
15 - Sleeve
16 - Countersunk screw, M5 x 16
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Installing cover for camshaft housing Page 6 of 10
ATTENTION
Risk of damage to the position sensor on the camshaft's trigger wheel!
The trigger wheel can be damaged when the cover of the camshaft housing is moved.
Ignition faulty.
Engine damage.
Note
The cover for the camshaft housing is removed and installed in the same way on cylinder bank 5 - 8 and
cylinder bank 1 - 4!
Note
Always replace inner and outer seal for camshaft housing!
Note
If the camshaft housing cover is not fitted carefully, it can cause the trigger wheel on the position sensor
at the rear on the camshaft to be bent out of shape!
3. Position the camshaft housing lid carefully; do not bend the trigger wheel of the position sensor on the
camshaft when doing so.
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Installing cover for camshaft housing Page 7 of 10
Note
It is best to use a tool that has an addendum of less than 50 mm
-A- (see special tool) to tighten the rear fastening screw on the
cylinder head cover close to the plenum panel.
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Installing cover for camshaft housing Page 8 of 10
Wiring harness
8. Fit wiring harness holder with new plastic clips. To do this, simply press on the wiring harness holder.
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Installing cover for camshaft housing Page 9 of 10
9. Connect the cable plug for the hydraulic valve and fit the cap.
10. Attach plug connection for the positive crankcase ventilation to the flange on the camshaft housing lid.
Ignition coil
13. Install bracket for torque support. Tighten the M8 x 45 Torx
screws at the top screw points. → Tightening torque: 17 ftlb.
Tighten the M6 x 40 screws at the bottom screw fastening points
(middle of valve cover). → Tightening torque: 9.5 ftlb.
Subsequent work
Subsequent work
1. Install ignition coils (ignition rod modules). Refer to→ 282055 Replacing ignition coils
2. Install secondary air pump with console. → 266519 Removing and installing secondary air pump -
Chapter "Installing".
3.
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Installing cover for camshaft housing Page 10 of 10
Install engine cover . → 108319 Removing and installing engine cover - Chapter "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\159123_0.htm 17.08.2011
Checking cooling system Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Checking cooling system Page 3 of 8
Tools
A - Cooling system leak tester (pump) see Workshop Equipment Manual, Chapter 3 "WE1069"
B - Hose extension FZ 100
C - K22 cap adapter (for sports cars)
D - K60 cap adapter included (in scope of delivery Filling device 9696 )
ATTENTION
Danger of poisoning!
Coolant additives and cleaning liquids are toxic.
DANGER
The vehicle fans can continue running or start up automatically.
Injuries which can lead to the loss of body parts.
→ The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or
the belt drive. → Disconnect fuse carrier [9PAAE1 9PAAE7 9PAAF1] → Disconnect fuse carrier [9PAAD1
9PAAD7 9PAAJ1] or battery → Work instructions after disconnecting the battery
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Checking cooling system Page 4 of 8
ATTENTION
Risk of damaging the cooling system!
→ Do not relieve the system pressure of the cooling system and then run the engine.
→ Relieving the system pressure and subsequently starting the engine can cause severe damage to
components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling
system to cool down before starting the engine again.
Note
The coolant filled in at the factory is intended to suffice for the entire service life. As long as the coolant is
not contaminated by foreign bodies or other fluids it need not be changed.
Different coolant additives must not be mixed and doing so may damage the cooling system. Only use
original Porsche coolant additives.
The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50 : 50
(coolant additive : water). This mixing ratio provides optimum corrosion and antifreeze protection.
Coolant additives, coolants and cleaning agents must be disposed of according to the respective,
applicable national laws.
Seals in the cooling system must be replaced by new ones following disassembly.
Maintenance cover
ATTENTION
Danger of scalding with hot coolant!
2. Carefully open the cap on the coolant reservoir. Unscrew the cap Cap on coolant reservoir
in an anti-clockwise direction.
3. Check antifreeze content with a commercially available antifreeze tester. If it is lower than -37 °C, it must
be adjusted accordingly. The coolant level must not drop below the minimum mark.
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Checking cooling system Page 5 of 8
Note
The following table specifies how much coolant must be replaced
by pure antifreeze in order to adjust the freezing point to -37 °C.
Note
The following diagram shows the scale used by Leitenberger.
Refractometer
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Checking cooling system Page 6 of 8
Pipette
2. Deposit a few drops on the test surface.
Note
The following table specifies how much coolant must be replaced
by pure antifreeze in order to adjust the freezing point to -37 °C.
Closing the light-diffusing lens
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Checking cooling system Page 7 of 8
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
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Checking cooling system Page 8 of 8
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\190101_0.htm 17.08.2011
Cooling system cleaned (after oil/coolant mixing) Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
ATTENTION
Danger of poisoning!
Coolant additives and cleaning liquids are toxic.
DANGER
The vehicle fans can continue running or start up automatically.
Injuries which can lead to the loss of body parts.
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Cooling system cleaned (after oil/coolant mixing) Page 3 of 5
→ The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or
the belt drive. → Disconnect fuse carrier [9PAAE1 9PAAE7 9PAAF1] → Disconnect fuse carrier [9PAAD1
9PAAD7 9PAAJ1] or battery → Work instructions after disconnecting the battery
ATTENTION
Risk of damaging the cooling system!
→ Do not relieve the system pressure of the cooling system and then run the engine.
→ Relieving the system pressure and subsequently starting the engine can cause severe damage to
components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling
system to cool down before starting the engine again.
Note
The coolant filled in at the factory is intended to suffice for the entire service life. As long as the coolant is
not contaminated by foreign bodies or other fluids it need not be changed.
Different coolant additives must not be mixed and doing so may damage the cooling system. Only use
original Porsche coolant additives.
The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50 : 50
(coolant additive : water). This mixing ratio provides optimum corrosion and antifreeze protection.
Coolant additives, coolants and cleaning agents must be disposed of according to the respective,
applicable national laws.
Seals in the cooling system must be replaced by new ones following disassembly.
Note
The cleaning work steps must be repeated until no more oil rises
to the surface in the coolant reservoir.
The cleaning agent is mixed with water at a ratio of 50:50 Draining cooling system
(Frostox R Spezial).
2. Fill the cooling circuit with the cleaning agent mixture. To do this, proceed with the cooling system
analogously to filling the coolant. → 193817 Draining and filling in coolant (includes bleeding) - chapter on
"Filling in"
4. After the vehicle has been bled and the coolant temperature is > 80 °C, let the stationary vehicle run at
medium engine speed for at least 15 minutes.
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Cooling system cleaned (after oil/coolant mixing) Page 4 of 5
ATTENTION
Danger of scalding with hot coolant!
8. Use hot water to rinse out any oil which has adhered inside the
coolant reservoir.
9. Close the cooling system and fill the coolant circuit with water
only and then bleed the cooling system according to regulations.
→ 193817 Draining and filling coolant (includes bleeding)
11. After the vehicle has been bled and the coolant temperature is > Coolant drain plug
80 °C, let the stationary vehicle run at medium engine speed for
at least 15 minutes.
ATTENTION
Danger of scalding with hot coolant!
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Cooling system cleaned (after oil/coolant mixing) Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\190129_0.htm 17.08.2011
Removing and installing electric fan Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
The small fan on the left is for the air conditioning - the big fan on the right is for engine cooling
Note
The big fan is for the engine cooling, the small fan is for the air conditioning
The sheetmetal clips on the fans are for balancing the fans and must not be pulled off.
1. Remove the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) -
chapter on "Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 21 Removing and
installing cooling fan housing (radiator frame) - chapter on "Removing" [9PAAJ1]
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Removing and installing electric fan Page 3 of 5
2. Undo the 3 fastening screws on fan and pull fan down and out.
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Removing and installing electric fan Page 4 of 5
1. Push fan cable with control module from underneath through the
radiator frame.
1. Push fan from the bottom into the frame and tighten the 3 fastening screws to 4 Nm (3 ftlb.).
2. Route connecting cables correctly and clip electric connector into the radiator frame at the top.
Subsequent work
Subsequent work
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Removing and installing electric fan Page 5 of 5
The small fan on the left is for the air conditioning - the big fan on the right is for engine cooling
Note
The big fan is for the engine cooling, the small fan is for the air conditioning
The sheetmetal clips on the fans are for balancing the fans and must not be pulled off.
1. Install the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) -
chapter on "Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and
installing cooling fan housing (radiator frame) - chapter on "Installing" [9PAAJ1]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\190819_0.htm 17.08.2011
Removing and installing radiator fan housing (radiator frame) Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Removing the front engine compartment cover. → 700219 Removing and reinstalling front cover (engine
compartment) - chapter on "Removing"
2. Remove Y-shaped pipes. → 243519 Removing and installing air box for throttle housing (Y-shaped pipe)
- chapter on "Removing" [9PAAF1]→ 243519 Removing and installing air box for throttle housing (Y-
shaped pipe) - chapter on "Removing" [9PAAD1 9PAAD7]→ 243519 Removing and installing air box for
throttle housing (Y-shaped pipe) - chapter on "Removing" [9PAAE1 9PAAE7]
DANGER
The vehicle fans can continue running or start up automatically.
Injuries which can lead to the loss of body parts.
→ The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or
the belt drive. → Disconnect fuse carrier [9PAAE1 9PAAE7 9PAAF1] → Disconnect fuse carrier [9PAAD1
9PAAD7] or battery → Work instructions after disconnecting the battery
Note
The repair instructions differ slightly in the illustrations for the V6. The work steps are essentially identical.
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Removing and installing radiator fan housing (radiator frame) Page 3 of 5
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2. Check whether the installation is correct. To do this, check whether the catch springs on the left and right
have engaged properly and that the four fastening projections on the underside have engaged in the
plastic clamps.
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Pressing the wiring harness into Electric connector for the fan
fastening clips
Subsequent work
Subsequent work
1. Install Y-shaped pipes. → 243519 Removing and installing air box for throttle housing (Y-shaped pipe) -
chapter on "Installing" [9PAAF1]→ 243519 Removing and installing air box for throttle housing (Y-shaped
pipe) - chapter on "Installing" [9PAAD1 9PAAD7]→ 243519 Removing and installing air box for throttle
housing (Y-shaped pipe) - chapter on "Installing" [9PAAE1 9PAAE7]
2. Install front engine cover. → 700219 Removing and reinstalling front cover (engine compartment) -
chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Draining and filling in coolant (includes bleeding) Page 2 of 12
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Special tools
Special tools 1
- - Flexible screwdriver a/f 7 (for loosening or tightening screw hose clamps) Flexible screwdriver a/f 7
A- NR.73-1
- - Antifreeze protection testing device (for checking the antifreeze content in the cooling system. The
B- design can deviate from that shown in the picture.)
- - Spring band clamp pliers (for opening and closing spring band clamps) Assembly tools for spring
C- band clamps NR.72
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-1- - Canister (canister with lifting tube, capacity approx. 30 l, with volume scale)
-2- - Hose extension
-3- - Adapter K 22 (included in the scope of delivery of radiator vacuum filling device)
-4- - Venturi nozzle (included in the scope of delivery of radiator vacuum filling device)
-5- - Adapter K 60 (included in the scope of delivery of radiator vacuum filling device)
-6- - Pressure gauge (included in the scope of delivery of radiator vacuum filling device)
Information
Note
Pay attention to the special features in the corresponding chapter for vehicles with auxiliary heater.
→ 193817 Draining and filling coolant (includes bleeding) - chapter on "Bleeding"
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Draining coolant
Draining coolant
ATTENTION
Danger of poisoning!
Coolant additives and cleaning liquids are toxic.
ATTENTION
Danger of scalding with hot coolant!
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→ Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause
scalding.
→ The cooling system must be depressurised before being opened.
→ Allow engine to cool down.
DANGER
The vehicle fans can continue running or start up automatically.
Injuries which can lead to the loss of body parts.
→ The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or
the belt drive. → Disconnect fuse carrier [9PAAE1 9PAAE7 9PAAF1] → Disconnect fuse carrier [9PAAD1
9PAAD7 9PAAJ1] or battery → Work instructions after disconnecting the battery
ATTENTION
Risk of damaging the cooling system!
→ Do not relieve the system pressure of the cooling system and then run the engine.
→ Relieving the system pressure and subsequently starting the engine can cause severe damage to
components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling
system to cool down before starting the engine again.
Note
The coolant filled in at the factory is intended to suffice for the entire service life. As long as the coolant is
not contaminated by foreign bodies or other fluids it need not be changed.
Different coolant additives must not be mixed and doing so may damage the cooling system. Only use
original Porsche coolant additives.
The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50 : 50
(coolant additive : water). This mixing ratio provides optimum corrosion and antifreeze protection.
Coolant additives, coolants and cleaning agents must be disposed of according to the respective,
applicable national laws.
Seals in the cooling system must be replaced by new ones following disassembly.
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Maintenance cover
2. Carefully open the cap on the coolant reservoir. Unscrew the cap in an anti-clockwise direction.
Engine guard
5. Release the front apron on the underside.
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8. Fit a new drain plug on the radiator and tighten it. If removed, fasten coolant hose.
9. Install the support plate under the radiator. Tighten the four
fastening screws. → Tightening torque: 17 ftlb.
3. Connect the vacuum pressure gauge of the bleeder tool to the flexible extension. When doing so, ensure
that both shut-off valves are closed (positioned at 90° to flow direction).
Note
The coolant amount provided must be approx. 2 litres more than
the amount which has to be filled. → Technical data for M48/00
engine (Cayenne S) [9PAAE1 9PAAE7]→ Technical data for
M48/00 engine (Cayenne S) [9PAAD1 9PAAD7 9PAAF1
9PAAJ1], → Technical data for M48/50 engine (Cayenne
Turbo) [9PAAF1 9PAAJ1]→ Technical data for M48/50 engine
(Cayenne Turbo) [9PAAD1 9PAAD7 9PAAE1 9PAAE7], →
Connecting the Venturi nozzle to the
Technical data for BFD engine (Cayenne ) [9PAAD1 9PAAD7]
vacuum pressure gauge
→ Technical data for BFD engine (Cayenne ) [9PAAE1 9PAAE7
9PAAF1 9PAAJ1]
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Draining and filling in coolant (includes bleeding) Page 9 of 12
Because differing quantities of coolant can drain away for different types of repairs, the filling capacities
can vary greatly. Recommendation: To be on the safe side, fill the canister to 30 l, then bleed the cooling
system. The difference after bleeding is the suctioned-in coolant quantity. Observe volume scale on the
canister.
5. Place a canister with a sufficient amount of coolant and with an antifreeze content of -35°C beside the
vehicle near the reservoir.
Note
The bleeding process is completed more quickly if the canister is positioned at roughly the same height
as the coolant expansion tank.
6. Push the filler hose -5- of the vacuum pressure gauge onto the canister connection. Lay the return line
-6- from the Venturi nozzle to a second container (bucket).
Note
A hissing sound after connecting the compressed air supply is
usual.
9. Close the left shut-off valve (V1) on the vacuum pressure gauge and allow a vacuum to build up in the
cooling system.
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Closing the left shut-off valve (V1) Shut-off valves on the vacuum
pressure gauge
Note
If no vacuum is generated
(the pointer does not
move to the green area),
there is a leak in the
cooling system.
After both shutoff valves on the vacuum pressure gauge have been closed and the compressed air
supply has been disconnected, the vacuum must not drop. If the vacuum drops within approx. 30
seconds, there is a leak in the coolant circuit.
10. When there is a sufficient vacuum in the cooling system (indicator is in the green area), close the right
shut-off valve (V2) and then disconnect the compressed air supply.
11. Re-open the left shut-off valve (V1) on the vacuum pressure gauge. The cooling system is then filled.
Note
If necessary, the system can be checked for leaks. → 190101 Checking cooling system - chapter on
"Checking"
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Reservoir cap
Note
Do not activate the 2/3 directional-control valve with the Porsche System Tester above 1500 rpm.
Activate the 2/3 directional-control valve with the Porsche System Tester below 1500 rpm.
3. Operate engine for 5 minutes with changing engine speeds. When doing this, run the engine for 10
seconds in idle and then for 10 seconds at 4,000 rpm. In the speed transition from higher engine speeds
(1500 to 4000 rpm) to idle (approx. 600), the directional-control valve should be activated with the
Porsche System Tester below 1500 rpm. Note that the 2/3 directional-control valve is not activated with
the Porsche System Tester above 1500 rpm.
6. Carefully open the cap on the coolant reservoir. Unscrew the cap in an anti-clockwise direction.
7. Check coolant level and, if necessary, fill the coolant reservoir with coolant to the maximum marking.
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Reservoir cap
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\193817_0.htm 17.08.2011
Removing and installing coolant expansion tank Page 2 of 7
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
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Removing and installing coolant expansion tank Page 3 of 7
Coolant hoses
3. Detach the torque support. To do this, unscrew the fastening
screw on the torque support bracket and pull it out.
6. Remove body bracket. When doing this, unclip the electric cable (2 x).
7. Loosen the secondary air pump from cylinder row 1-4. → 266519 Removing and installing secondary air
pump - chapter on "Removing"
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Removing and installing coolant expansion tank Page 4 of 7
Fastening screw
9. Pull coolant reservoir towards engine and take out of the holder.
Coolant reservoir
1. Insert coolant reservoir into the holder and push in the direction
of the wing.
Coolant reservoir
2. Tighten fastening screw. → Tightening torque: 7.5 ftlb.
3. Tighten the secondary air pump from cylinder row 1-4. → 266519 Removing and installing secondary air
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Removing and installing coolant expansion tank Page 5 of 7
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Coolant hoses
10. Connect electric plug to reservoir.
Subsequent work
Subsequent work
1. Install the engine compartment cover at the right and rear. → 700219 Removing and reinstalling front
cover (engine compartment) - chapter on "Installing"
2. Install right headlight. → 941519 Removing and installing main headlight - chapter on "Installing"
3. Fill and bleed the cooling system. → 193817 Draining and filling coolant (includes bleeding) - chapter on
"Filling"
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Removing and installing coolant expansion tank Page 7 of 7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\194019_1.htm 17.08.2011
Removing and installing additional coolant pump Page 2 of 4
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Undo sheetmetal holder of coolant line by removing fastening screw (M6 x 16) on the body. Unclip the
coolant line from the holder. Carefully pull the additional coolant pump forward under the wing. Pull off
file://C:\POSES\data\rl\2\9PA\194519_0.htm 17.08.2011
Removing and installing additional coolant pump Page 3 of 4
Subsequent work
Subsequent work
Note
If necessary, the system can be checked for leaks. → 190101 Checking cooling system
1. Fill and bleed the cooling system. → 193817 Draining and filling coolant (includes bleeding) - chapter on
"Filling"
file://C:\POSES\data\rl\2\9PA\194519_0.htm 17.08.2011
Removing and installing additional coolant pump Page 4 of 4
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\194519_0.htm 17.08.2011
Removing and installing coolant pump Page 2 of 9
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Radiator frame
Information
file://C:\POSES\data\rl\2\9PA\195019_0.htm 17.08.2011
Removing and installing coolant pump Page 3 of 9
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Removing and installing coolant pump Page 4 of 9
1 - Coolant pump
2 - Seal for coolant pump (replace seal)
3 - 2 dowel sleeves (do not remove)
4 - 8 M6x25 fastening screws (tightening torque 10 Nm (7.5 ftlb.))
5 - Support for cable duct (fit with the two upper fastening screws)
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.
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Removing and installing coolant pump Page 5 of 9
Note
To ease removal, spray the pulley from the rear side with an anti-
corrosion agent.
Belt tensioner
ATTENTION
Risk of damaging pulley!
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Removing and installing coolant pump Page 6 of 9
ATTENTION
Risk of damaging pulley!
→ The pulleys of the engine accessories are made of plastic. Do not use damaged pulleys.
→ The pulley is sensitive to impacts.
→ Do not prise off the pulley with a screwdriver.
1. Clean sealing surfaces. Mount new sheetmetal seal on the coolant pump. Slide the new sheetmetal seal
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Removing and installing coolant pump Page 7 of 9
3. Fit the pulley on the coolant pump. Screw in the three fastening
screws by hand.
4. Mount drive belt -as shown in the following- . To do this, turn
the belt tensioner clockwise and thread the drive belt around all
the pulleys. Then carefully relieve the tensioning roller .
→ 137819 Removing and installing drive belt - chapter on
"Installing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing
drive belt - chapter on "Installing" [9PAAE1 9PAAE7] Mount the fastening screws for the
coolant pump
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Removing and installing coolant pump Page 8 of 9
8. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the
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Removing and installing coolant pump Page 9 of 9
sheetmetal holder.
Subsequent work
Subsequent work
1. Install the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) -
chapter on "Installing" [9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and installing cooling fan
housing (radiator frame) - chapter on "Installing" [9PAAJ1]
2. Fill and bleed the cooling system according to instructions. → 193817 Draining and filling coolant
(includes bleeding) - chapter on "Filling"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\195019_0.htm 17.08.2011
Removing and installing coolant regulator (thermostat) Page 2 of 10
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
file://C:\POSES\data\rl\2\9PA\195819_0.htm 17.08.2011
Removing and installing coolant regulator (thermostat) Page 3 of 10
Information
Component overview
Install location
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Removing and installing coolant regulator (thermostat) Page 4 of 10
Component overview
Removing thermostat
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Removing and installing coolant regulator (thermostat) Page 5 of 10
7. Disconnect vent line for cylinder heads. To do this, press the ribbed surfaces of the buttons and pull off
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Removing and installing coolant regulator (thermostat) Page 6 of 10
Button on the vent lines of cylinder Fastening screw for coolant return line
heads to thermostat housing
the plugs.
10. Lift the housing cover. Remove the thermostat using assembly aid 9627.
Installing thermostat
Note
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Removing and installing coolant regulator (thermostat) Page 7 of 10
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Removing and installing coolant regulator (thermostat) Page 8 of 10
4. Tighten the three rear fastening screws (M6 x 16) on the heater
pipes. → Tightening torque: 7.5 ftlb.
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Removing and installing coolant regulator (thermostat) Page 9 of 10
7. Push coolant line onto generator and fit the spring-band clamp.
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Removing and installing coolant regulator (thermostat) Page 10 of 10
Subsequent work
Subsequent work
1. Install intake distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Installing"
2. Fill coolant system and check for leaks. → 193817 Draining and filling coolant (includes bleeding) -
chapter on "Filling"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\195819_0.htm 17.08.2011
Removing radiator Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Disconnect battery. → 90 Work instructions after disconnecting the battery
2. Drain cooling system. → 193817 Draining and topping up with coolant (includes bleeding) - chapter on
"Draining"
3. Remove lock mount. → 503819 Removing and installing lock mount - chapter on "Removing"
4. Remove the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) -
chapter on "Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 21 Removing and
installing cooling fan housing (radiator frame) - chapter on "Removing" [9PAAJ1]
Information
Component overview
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Removing radiator Page 3 of 6
Overview of radiator
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Removing radiator
Do not open the air conditioner if at all possible when removing the - radiator module. Do not bend the lines
Note
The retaining clips should be mounted again immediately so that they are not confused.
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Removing radiator Page 5 of 6
6. Lift both locks for the ATF cooler and air-conditioning condenser with a screwdriver -1- and push down
-arrow- .
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Removing radiator Page 6 of 6
Note
Fix the remaining radiators in the installation position using tie
wraps.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\197021_0.htm 17.08.2011
Installing radiator Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Component overview
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Installing radiator Page 3 of 6
Overview of radiator
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Installing radiator Page 4 of 6
Installing radiator
Note
The retaining clips should be mounted again immediately so that they are not confused.
Do not open the air conditioner if at all possible when removing the - radiator module. Do not bend the lines
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Installing radiator Page 5 of 6
2. Move the ATF cooler into the installation position and push on
the metal clips to fasten it.
5. Screw in both fastening screws -C- for securing condenser to the coolant radiator (left direction of travel).
→ Tightening torque: 6 ftlb.
6. Push on the cooler vent line onto the right radiator side and fit the spring-band clamp.
7. Push on the two coolant lines. The retaining clips on the flange must engage audibly.
file://C:\POSES\data\rl\2\9PA\197023_0.htm 17.08.2011
Installing radiator Page 6 of 6
Fastening screws for securing Fastening screw for servo oil coolant
condenser to coolant radiator line
Pushing on coolant lines Spring band clamp for cooler vent line
Subsequent work
Subsequent work
1. Install the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) -
chapter on "Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and
installing cooling fan housing (radiator frame) - chapter on "Installing" [9PAAJ1]
2. Install lock mount. → 503819 Removing and installing lock mount - chapter on "Installing"
3. Fill and bleed the cooling system. → 193817 Draining and filling in coolant (includes bleeding) - chapter
on "Filling in"
4. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "Installing"
5. Connect the battery . → 90 Work instructions after disconnecting the battery
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\197023_0.htm 17.08.2011
Removing and installing coolant temperature sensor Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Draining coolant
Information
Component overview
Installation Location:
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Removing and installing coolant temperature sensor Page 3 of 6
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Removing and installing coolant temperature sensor Page 4 of 6
Component overview
1 - Distributor pipe
2 - Coolant temperature sensor (when removing, collect emerging coolant, when installing, replace sealing
ring)
3 - Sealing ring (replace when installing)
4 - 3 screw plugs, M16x1 (when removing, collect emerging coolant, when installing, replace sealing ring)
5 - 10 hexagon-head bolts M6x25
6 - 2 seals for distributor pipe (when installing, clean sealing faces and replace seal)
7 - 4 sealing rings (when installing, grease with Klüber Syntheso GLEP 1
8 - Lower cooling water tube
ATTENTION
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Removing and installing coolant temperature sensor Page 5 of 6
Danger of poisoning!
Coolant additives and cleaning liquids are toxic.
ATTENTION
Danger of scalding with hot coolant!
→ Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause
scalding.
→ The cooling system must be depressurised before being opened.
→ Allow engine to cool down.
Note
Even when the coolant has been completely drained, coolant
emerges from the open bore on the coolant temperature sensor!
1. Clean sealing surfaces and screw in coolant temperature sensor with a new sealing ring into the
distributor pipe. → Tightening torque: 22 ftlb.
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Removing and installing coolant temperature sensor Page 6 of 6
Subsequent work
Subsequent work
1. Install intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Installing"
2. Fill up completely with coolant and bleed system. → 193817 Draining and filling coolant (includes
bleeding) - chapter on "Filling".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\197819_0.htm 17.08.2011
Checking fuel pressure Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\200201_0.htm 5/19/2011
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Special tools
Special tools
Information
Test conditions
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Checking fuel pressure Page 5 of 6
Design cover
3. Connect connection line 9559 to the pressure gauge p378 . Screw
the other end onto the fuel gallery.
Connection line
4. Switch on the ignition and start the engine. Read off fuel pressure on
pressure gauge. The value must be 4.0 ± 0.2 bar at idle speed.
Pressure gauge
DANGER
Danger of fire due to incorrect or faulty scavenging valves!
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Checking fuel pressure Page 6 of 6
Note
The steady-state pressure must be greater than 2.0 bar after 1 hour.
5. Unscrew connection line and close the fuel gallery with a new plastic
cap.
Connection line
6. Press the 4 rubber elements in the cover onto the 4 ball head
supports. The mounts must be felt to engage.
Design cover
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing fuel tank Page 3 of 9
Preliminary work
2. Remove the carbon canister. Details for loosening in installation location (wheel housing) see → 202521
Removing carbon canister. The degassing tank is removed with the fuel tank connected (joined).
3. Remove rear axle (spring struts and rear axle housing) push it aside on the lifting platform (scope of work
without further disassembly of rear axle) → 420519 Removing and installing rear axle housing - chapter on
"Removing"
Required tools
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Removing fuel tank Page 4 of 9
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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Note
The repair procedure may vary depending on engine type and country equipment. This relates in particular to
components in the right wheel housing.
The following exploded drawing shows how the fuel tank is attached to the vehicle floor.
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2. Screw the tank cap down. Then remove the rubber sleeve around the
fuel filler neck, loosen the two fastening screws M6 x 25 and remove
the ground cable.
Connection unit
4. Pull fuel filler neck and degassing tank out of the wheel housing and
secure with a piece of wire arrow -arrow- (picture shows degassing
tank with carbon canister).
6. Remove line holder under the stone shield by pressing on the centre plug -arrow- . Replace holder.
7. Remove the centre underbody cover at the left and right of the longitudinal side members. → 519319
Removing and installing centre cover - chapter on "removing"
8. Remove rear heat shield. To do so, undo the three speed nuts and the two screws.
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DANGER
Danger of injury due to heavy filled tank!
→ For safety reasons, the tank should only be removed and installed
when empty!
9. Loosen the tank attachment band, which runs in the direction of travel
-arrows- . Then, position a transmission jack under the tank and
secure the tank from falling using a belt. When doing so, make sure
that the fuel lines are not damaged.
Tank attachment band
ATTENTION
Risk of damaging to fuel lines!
Lines can become kinked or can crack.
10. Undo and remove the remaining restraining straps with the help of a
second worker. Slowly lower the tank with the transmission jack. Also
carefully guide the degassing tank in the right wheel housing. Tank on lever
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\201021_0.htm 5/19/2011
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Required tools
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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.
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→ Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
Note
The repair procedure may vary depending on engine type and country equipment. This relates in particular to
components in the right wheel housing.
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The following exploded drawing shows how the fuel tank is attached to the vehicle floor.
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Note
The top left cover must be fitted before the tank is installed.
When installing the tank and rear axle, make sure that cables and lines
are not damaged and are in the correct installation position.
When introducing the tank into the body, a second person should
guide the degassing tank and safeguard it against damage using wire.
1. Raise the tank with a transmission jack. Make sure to secure the tank
with a tension strap to prevent it from falling.
2. With the help of a second worker, put the tank into the installation position. A second person should carefully
guide the degassing tank.
Note
Note direction arrow stamped on the restraining straps and install
these in the direction of travel.
3. Attach lower covers and fit the four restraining straps, which run at
right angles to the direction of travel. Make sure that the stamped
arrow is pointing forwards in the direction of travel. Tighten fastening
screws to the specified tightening torque. → Tightening torque: 17
ftlb. Secure fuel filler neck and degassing tank again with a wire
-arrow- .
Figure shows secured degassing tank
(shown here with carbon canister
attached)
4. Lower the transmission jack and fit the centre restraining strap. The
arrow must be pointing forwards. Tighten fastening screws to the
specified torque. → Tightening torque: 17 ftlb.
file://E:\POSES\data\rl\2\9PA\201023_0.htm 5/19/2011
Installing fuel tank Page 8 of 9
6. Mount the underbody panel of the side member on the left and right. → 519319 Removing and installing
middle cover
Holder
8. Then, fit the stone guard on the right side. Mount nuts -arrows- and
tighten to the specified torque. → Tightening torque: 7.5 ftlb.
Stone guard
9. Mount the fuel supply -1- to the connection unit and connect the 2
connection points -2 and 3- .
Connection unit
file://E:\POSES\data\rl\2\9PA\201023_0.htm 5/19/2011
Installing fuel tank Page 9 of 9
Subsequent work
Subsequent work
4. Mount rear axle (spring struts and rear axle housing). → 420519
Removing and installing rear axle housing - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\201023_0.htm 5/19/2011
Removing and installing fuel level sensor Page 2 of 9
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Information
Component information
Note
The two senders have different shapes and may not be switched.
The float installed in the left direction of travel is flat, while the float installed in the right direction of travel is
spherical.
The removal of both senders is explained in parallel in this description. If only one sender has to be removed,
the other side of the tank can remain untouched.
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Removing and installing fuel level sensor Page 3 of 9
The effect of fuel and various tolerances means that the left fuel level sensor can become jammed under fuel lines
or the sensor's electric cable. The instrument cluster would then display an incorrect fuel level.
To prevent this, the two fuel lines coming from the left pump and the
electric cable should be tied together with a tie-wrap following repairs.
Preliminary work
Installation Location:
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Removing and installing fuel level sensor Page 4 of 9
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.
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. →
Draining and filling fuel
DANGER
file://E:\POSES\data\rl\2\9PA\201519_0.htm 5/19/2011
Removing and installing fuel level sensor Page 5 of 9
→ Gasoline is toxic.
→ Inhaling vapours 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. Fuel supply and disconnection points
→ Wear protective gloves that at right connection unit
are fuel-resistant.
→ Wear a breathing mask with
active charcoal filter; do not
breathe in any fuel vapours.
→ Ensure that there is adequate
ventilation and extract all fuel
vapours.
→ 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.
DANGER
Danger of fire from fuel!
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Removing and installing fuel level sensor Page 6 of 9
→ 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 CO2 or dry powder fire extinguishers.
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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.
7. Open the relevant cap with the key T10202 and lift up the connection
unit (cap).
Cap
Preliminary work
1. Disconnect electric connectors -1 and 2- . Then pull off the fuel lines
-3 and 4- and remove the connection unit.
Connection unit
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Removing and installing fuel level sensor Page 7 of 9
2. Press the retaining spring on the sender by hand while at the same
time pulling the sender up.
1. Install a new tank gauge. Press the sender into its mounting. The
retaining spring must engage audibly.
Subsequent work
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Removing and installing fuel level sensor Page 8 of 9
Subsequent work
3. Fit connection unit into tank opening. When doing so, make sure that
the plastic lug is pointing forwards.
Connection unit
Closing the tank
1. Close the tank. To do so, fit the sheetmetal ring and tighten using the
key T10202. → Tightening torque: 104 ftlb.
Cap
2. Fit all connections (fuel lines, ventilation tubes and electric plugs).
file://E:\POSES\data\rl\2\9PA\201519_0.htm 5/19/2011
Removing and installing fuel level sensor Page 9 of 9
4. Tighten the seat-belt buckle fastening plates. Use three new fastening
screws for this and tighten. For tightening torque, see → 692519
Removing and installing rear belt lock .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\201519_0.htm 5/19/2011
Removing carbon canister Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Take up the vehicle at the jacking points provided using a platform lift. → Lifting the vehicle [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1]
3. Screw the tank cap down. Then remove the rubber sleeve around the
tank filler neck, loosen the 2 M6 x 20 fastening screws and remove the
ground cable.
4. Remove right rear wheel. → 440519 Removing and installing wheel -
chapter on "Removing".
file://E:\POSES\data\rl\2\9PA\202521_0.htm 5/19/2011
Removing carbon canister Page 3 of 8
DANGER
Rear wheel housing liner
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 Mud flap
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 vapours.
→ Ensure that there is adequate
ventilation and extract all fuel
vapours.
→ 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.
DANGER
Danger of fire from fuel!
file://E:\POSES\data\rl\2\9PA\202521_0.htm 5/19/2011
Removing carbon canister Page 4 of 8
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
Information
Component information
ATTENTION
Risk of damage!
There is a risk of leaks if the overflow line on the fuel filler neck is above the valve.
file://E:\POSES\data\rl\2\9PA\202521_0.htm 5/19/2011
Removing carbon canister Page 5 of 8
Note
The repair procedure may vary depending on engine type and country equipment. This relates in particular to
components in the right wheel housing.
The following exploded drawing shows the attachment of the tank filler neck and carbon canister in the right wheel
housing.
file://E:\POSES\data\rl\2\9PA\202521_0.htm 5/19/2011
Removing carbon canister Page 6 of 8
1 - Fastening screw, M6 x 28
2 - Fastening screw M6 x 20
3 - Fastening screw
4 - Fastening screw M6 x 28
5 - Fastening nut M6
6 - Carbon canister
7 - Degassing tank
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Removing carbon canister Page 7 of 8
ATTENTION
Risk of damage!
Lines can become kinked or can crack.
1. Loosen the 5 fastening screws on the carbon canister and the two on
the degassing tank in the right wheel housing -arrows- .
Fastening screws
Note
In USA vehicles, the rubber hose -2- of the leak diagnosis pump is
extremely tight. If the hose is pulled, the connection piece can break
off at the leak diagnosis pump.
Cutting tie-wraps
4. Remove hose connection on the degassing tank.
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Removing carbon canister Page 8 of 8
ATTENTION
Risk of damage!
Lines can become kinked or
can crack.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\202521_0.htm 5/19/2011
Installing carbon canister Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
file://E:\POSES\data\rl\2\9PA\202523_0.htm 5/19/2011
Installing carbon canister Page 3 of 8
→ 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 CO2 or dry powder fire extinguishers.
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
Component information
file://E:\POSES\data\rl\2\9PA\202523_0.htm 5/19/2011
Installing carbon canister Page 4 of 8
Note
The repair procedure may vary depending on engine type and country equipment. This relates in particular to
components in the right wheel housing.
The following exploded drawing shows the attachment of the tank filler neck and carbon canister in the right wheel
housing.
file://E:\POSES\data\rl\2\9PA\202523_0.htm 5/19/2011
Installing carbon canister Page 5 of 8
1 - Fastening screw, M6 x 28
2 - Fastening screw M6 x 20
3 - Fastening screw
4 - Fastening screw M6 x 28
5 - Fastening nut M6
6 - Carbon canister
7 - Degassing tank
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Installing carbon canister Page 6 of 8
1. Replace the ground cable tie-wraps on the carbon canister and pre-assemble the ground cable. Lift the
carbon canister into the wheel housing.
2. Join all lines on the carbon canister and degassing tank at the plug connections.
ATTENTION
Risk of damage!
There is a risk of leaks if the overflow line on the fuel filler neck is
above the valve.
5. Swivel carbon canister down into installation position from behind. Degassing tank
Make sure that the fuel overflow line -1- is below the solenoid valve -2-
. If the line is not routed correctly, this will cause damage during
subsequent operation.
Picture shows the correct position of the line. View from above without rear side panel.
file://E:\POSES\data\rl\2\9PA\202523_0.htm 5/19/2011
Installing carbon canister Page 7 of 8
1 - Overflow line
2 - Solenoid valve
Fastening screws
Subsequent work
Subsequent work
1. Install the right rear wheel housing liner. → 536919 Removing and installing rear wheel housing liner - chapter
on "Installing"
2. Mount rear wheel. → 440519 Removing and installing wheel - chapter on "Installing"
3. Connect ground cable to fuel filler neck. Screw down the 2 fastening screws and mount rubber sleeve around
the tank filler neck. → Tightening torque: 7.5 ftlb.
file://E:\POSES\data\rl\2\9PA\202523_0.htm 5/19/2011
Installing carbon canister Page 8 of 8
Mud flap
5. Activate air suspension.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\202523_0.htm 5/19/2011
Fuel filter lines checked (in tank) Page 2 of 5
Information
Installation Location:
file://E:\POSES\data\rl\2\9PA\204302_0.htm 5/19/2011
Fuel filter lines checked (in tank) Page 3 of 5
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Fuel filter lines checked (in tank) Page 4 of 5
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Fuel filter lines checked (in tank) Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\204302_0.htm 5/19/2011
Removing and installing leakage diagnosis pump (LDP) Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
file://E:\POSES\data\rl\2\9PA\204819_0.htm 5/19/2011
Removing and installing leakage diagnosis pump (LDP) Page 3 of 8
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
Preliminary work
Preliminary work
1. Remove carbon canister and place it on a clean surface. → 202521 Removing carbon canister
Information
Component information
file://E:\POSES\data\rl\2\9PA\204819_0.htm 5/19/2011
Removing and installing leakage diagnosis pump (LDP) Page 4 of 8
1 - Degassing tank
2 - Filler neck
3 - Pressure control valve
4 - Carbon canister
5 - Leakage diagnosis pump
1. Loosen three fastening screws on plastic support for pressure control valve. -Arrows-
To remove the top fastening screw, carefully press the pressure control valve hose aside using a screwdriver
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Removing and installing leakage diagnosis pump (LDP) Page 5 of 8
2. Turn the pressure control valve to the side and remove the three
fastening screws on the leakage diagnosis pump. → Pressure control
valve and leakage diagnosis pump mount
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Removing and installing leakage diagnosis pump (LDP) Page 6 of 8
Rubber flange
1. If the rubber flange slips out of the housing and remains on the connection piece of the leakage diagnosis
pump while you are removing the leakage diagnosis pump, check the rubber flange for damage and insert it
back flush into the carbon canister housing if it is OK. → Rubber flange → Inserted rubber flange
2. Lightly lubricate the connection piece of the leakage diagnosis pump and rubber flange with KLUEBER
Syntheso Glep 1 (000 043 204 68 status 12/05) and carefully move leakage diagnosis pump into installation
position. Make sure that the rubber flange is not pushed into the housing.
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Removing and installing leakage diagnosis pump (LDP) Page 7 of 8
3. Ensure that the leakage diagnosis pump is seated correctly in the bracket for the active carbon filter. Fit the
three fastening screws for the leakage diagnosis pump → Tightening torque: 3 (2 ftlb.) Nm and turn
pressure control valve back into installation position. → Pressure control valve and leakage diagnosis pump
mount
5. Fit three fastening screws on the plastic support for the pressure control valve → Tightening torque: 3 (2
ftlb.) Nm . -Arrows-
To fit the top fastening screw, carefully press the pressure control valve hose aside using a screwdriver and
screw in the fastening screw. → Pressure control valve
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Removing and installing leakage diagnosis pump (LDP) Page 8 of 8
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\204819_0.htm 5/19/2011
Removing and installing fuel filter Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
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)
file://E:\POSES\data\rl\2\9PA\206019_0.htm 5/19/2011
Removing and installing fuel filter Page 3 of 8
Note
If the tank must be opened for emptying, disconnect all connections.
Installation Location:
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.
file://E:\POSES\data\rl\2\9PA\206019_0.htm 5/19/2011
Removing and installing fuel filter Page 4 of 8
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. →
Draining and filling fuel
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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. Fuel supply and disconnection points
→ Wear a breathing mask with active charcoal filter; do not breathe in at right connection unit
any fuel vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
file://E:\POSES\data\rl\2\9PA\206019_0.htm 5/19/2011
Removing and installing fuel filter Page 5 of 8
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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.
7. Open the relevant cap with the key T10202 and lift up the connection
unit (cap).
Cap
Information
Component overview
file://E:\POSES\data\rl\2\9PA\206019_0.htm 5/19/2011
Removing and installing fuel filter Page 6 of 8
1. Disconnect electric connectors -1 and 2- . Then pull off the fuel lines
-3 and 4- and remove the filter unit.
Connection unit
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Removing and installing fuel filter Page 7 of 8
Seal
2. Connect filter unit. Mount the electric connector -1 and 2- and the
hose connections -3 and 4- .
3. Place the connection unit into the tank. When doing so, make sure
that the plastic lug is pointing forwards.
Connection unit
Subsequent work
1. Close the tank. To do so, fit the sheetmetal ring and tighten using the
key T10202. → Tightening torque: 104 ftlb.
Cap
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
file://E:\POSES\data\rl\2\9PA\206019_0.htm 5/19/2011
Removing and installing fuel filter Page 8 of 8
tightening torque, see → 692519 Removing and installing rear belt lock .
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\206019_0.htm 5/19/2011
Checking quantity of fuel delivered Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Special tools
Information
Test conditions
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WARNING
Danger of fire and injury!
Danger of fire due to escaping fuel, e.g. on hot engine
components or due to electrostatic charge.
Danger of fire due to naked flames and sparks, e.g. during
welding or grinding work.
Note
The fuel gallery is pressurised! Place a cloth near the front of the fuel gallery to prevent fuel dripping onto hot
engine parts.
3. Join the test hose to the measuring adapter and connect the other end to the scavenging valve on the fuel
gallery.
Note
For the delivery rate check, a second person should clock the time.
4. Place the open hose end from the pressure regulator in the measuring beaker.
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Note
To avoid incorrect readings, make sure that the hose lines are
already full of fuel at the start of the test.
6. Keep fuel pump switched on until fuel emerges from the end of the
hose. Then empty the measuring beaker.
Test setup
7. Switch on fuel pump I (left pump) for one minute. Then monitor the fuel delivered and note the quantity. Now
repeat the process with pump II (right pump).
If the test delivery rate produced in the test is too low, repeat it at the right scavenging valve of the fuel gallery.
8. On completion of the test, switch off the ignition and remove test tool.
DANGER
Danger of fire due to faulty scavenging valves!
9. Press the four rubber elements in the cover onto the four ball socket
holders. The mounts must be felt to engage.
Cover
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\206601_0.htm 5/19/2011
Removing and installing fuel pump Page 2 of 12
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Empty the fuel tank. → Draining and filling fuel
Information
General note
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Note
The fuel pumps have different hose connections and must not be confused.
In order that the connections do not fall in the fuel tank, they should be secured using tie-wraps.
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Installation Location:
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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.
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. →
Draining and filling fuel
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DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 Fuel supply and disconnection points
periods. at right connection unit
→ 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 vapours.
→ Ensure that there is adequate
ventilation and extract all fuel
vapours.
→ 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.
DANGER
Danger of fire from fuel!
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→ 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 CO2 or dry powder fire extinguishers.
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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.
7. Open the relevant cap with the key T10202 and lift up the connection
unit (cap).
Cap
Removing left fuel pump
1. Pull off electric connectors -1 and 2- on the left connection unit. Then pull off the fuel lines -3 and 4- and
remove the connection unit (filter unit).
2. Disconnect the sucking jet pump at the fuel pump. To do this, press on the left and right and pull off the
connection.
3. Raise the right connection unit slightly and disconnect the fuel pump line at the Y-piece (on the right side).
4. Turn the pump approx. 90° to the left until it disengages at the tank floor. Remove the pump from the tank.
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Sucking jet pump connection at the Electric connectors and fuel lines
fuel pump
Removing right fuel pump
3. Disconnect the hose for the right fuel pump at the Y-piece.
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2. Connect the fuel line from the pump to the Y-piece (right side of the tank).
3. Attach the sucking jet pump connection. This must engage audibly.
6. Place the connection unit into the tank. When doing so, make sure that the plastic lug is pointing forwards.
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1. Place the pump in the holder on the tank floor and turn it approx. 90°
to the right until it is seated securely.
2. Connect the fuel line from the right pump to the Y-piece.
5. Connect connection unit. Connect the electric connectors for the tank
gauge and fuel pump. Then push on the fuel lines. The connectors
must engage audibly.
6. Place the connection unit into the tank. When doing so, make sure
that the plastic lug is pointing forwards.
1. Close the tank. To do so, fit the sheetmetal ring and tighten using the
key T10202. → Tightening torque: 104 ftlb.
Cap
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2. Fit all connections (fuel lines, ventilation tubes and electric plugs).
Subsequent work
Subsequent work
1. Fill fuel tank (refuel). → Draining and filling fuel
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
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C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Special tool
A - Fuel transfer unit (This tool has been tested and approved by PORSCHE.); see Workshop
Equipment Manual 3.2.2. "WE 1262"
B - Fuel nozzle - special accessory (This can be used to refuel the vehicle. The fuel nozzle
switches off automatically as soon as the fuel tank is full.); see Workshop Equipment Manual
3.2.2 "WE 1262"
C - Porsche adapter (This adapter fits 8-mm to 10-mm fuel lines (986; 996 and Cayenne.); see
Workshop Equipment Manual 3.2.2 "WE 1262"
D - Connecting piece between Porsche adapter and suction line (This is screwed into suction line
E and connected to the Porsche adapter.); see Workshop Equipment Manual 3.2.2 "WE 1262"
E - Suction line with venting device (Always attach venting device (rubber taper with transparent
hose) to the filler neck. This minimises the amount of escaping fuel vapours.); see Workshop
Equipment Manual 3.2.2. "WE 1262"
ohne - Adapter adapter 9479 (For controlling the fuel pumps); see Workshop Equipment Manual,
Bezeichnung Chapter 2.2.2
Information
Using equipment
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1. Connect the fuel hose -1- to the changeover tank. Connect the
venting device (transparent hose) to the changeover tank. Then
attach the pneumatic stop switch -3- to the tank and tighten the two
knurled nuts.
2. Connect the suction hose (or fuel nozzle) to the connection -1- and
then connect the venting device -2- .
Note
Fuel can be removed directly through the fuel filler neck on older vehicles or vehicles from other
manufacturers by removing the connecting piece.
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DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
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ATTENTION
Damage to the fuel tank!
→ Please observe the general warning notes and working regulations. → 10 The most important working
regulations and warning notes.
→ The tank can only be drained using the vehicle's own fuel pumps.
→ It is not possible to extract fuel via the fuel filler opening and doing so may cause damage.
Note
All windows should be opened for better ventilation in the passenger compartment.
4. Reduce the fuel pressure in the fuel line. To do so, screw down the
protective cap on the fuel gallery and carefully press the valve.
Collect emerging fuel with a cloth.
Cap
5. Carefully pull off the fuel line -1- . Collect emerging fuel with a cloth.
7. Attach Porsche adapter to the connection piece. Twist top and bottom part of adapter in opposite directions
until it is tight.
8. Screw the connecting piece into the suction hose and tighten it hand tight.
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ATTENTION
Risk of damage to fuel pumps!
The Porsche adapter can slip from the tank connection.
→ Only switch fuel pumps on after the extraction pump has been
switched on.
→ Always set extraction pump to suction mode - never refill mode -
when the vehicle pump is running. Lid of central electrics box
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Note
Use special tool adapter 9479 from the measurement tool box to activate the fuel pump.
Alternatively, adapters 26 and 25 can be connected and the fuel relay can be bridged. A fault is stored in the
engine control module during this procedure.
11. Remove fuel pump relays -1- and -2- . The pump can be activated by bridging the relevant contacts. The
contact assignment is printed on the corresponding relay. No faults are stored in the engine control module
when special tool adapter 9479 is used. Both pumps should be activated. As soon as the tank is empty, fit
the fuel pump relays again and close the electrics box.
12. Carry out any necessary repair work on the tank. Please observe the warning notes in the chapter entitled
→ 10 The most important working regulations and warning notes.
13. Fit all connections (fuel lines, ventilation tubes and electric plugs).
Connections
14. Fit the lid. Then tighten the four fastening nuts → Tightening torque: 10 (7.5 ftlb.) Nm . Refit carpeted floor
and fix with double-sided adhesive tape.
15. Tighten the seat-belt buckle fastening plates. Use three new fastening screws for this and tighten. For
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tightening torque see → 692519 Removing and installing rear belt lock
16. Fold rear seat down again.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
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. → 700219 Removing
and installing front cover (engine compartment)
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.
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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
Air line
2. Push the circlip into the flange -1- and then pull it off together with the
flange -2- .
Connection
3. Clip the green cap on again after disassembly.
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.
5. Open the two upper fastening clips on the air cleaner housing.
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Clamps
11. Push the air suspension line onto the right air cleaner cover.
Subsequent work
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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. → 700219 Removing
and installing front cover (engine compartment)
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\242455_1.htm 5/19/2011
Removing and installing air cleaner housing Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
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. → 505619 Removing and installing front wheel housing liner.
Component overview
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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.
3. Unclip the electric cable from the coolant expansion tank on the cylinder bank 1 - 4. The cable is clipped in at
2 points.
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1. Insert the air cleaner housing into the engine compartment at an angle
from above.
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Fastening screw
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.
Electric cable
5. Replace the air guide on the air cleaner housing from the wheel well.
Check that the elements are installed correctly.
Air guide
Subsequent work
Subsequent work
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. → 505619 Removing and installing front wheel housing liner.
9PAAE1, 9PAAE7
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Removing cowl for throttle housing (Y-shaped pipe) - Cayenne S (type M48/00)
1. Remove front engine compartment cover. → 700219 Removing and installing front cover (engine
compartment) - "Removing" section
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.
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Fastening bolts
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
5. Remove the fastening bolts. To do this, take hold of the bolt by the
rubber ring with pliers and pull it out.
Bellows
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Vacuum line
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)
Vacuum line
2. Slide the bellows onto the air flow sensors and tighten the hose
clamps.
Bellows
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
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. → 700219 Removing and installing front cover (engine compartment)
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9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing fuel injector Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
2. Remove design covers from engine. → 108319 Removing and installing engine cover - "Removing" section
Component overview
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Removing and installing fuel injector Page 3 of 7
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
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Removing and installing fuel injector Page 4 of 7
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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. Fuel connections
→ Wear a breathing mask with active charcoal filter; do not breathe in
any fuel vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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Removing and installing fuel injector Page 5 of 7
1. Disconnect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel.
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.
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Removing and installing fuel injector Page 6 of 7
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- .
Valve alignment
3. Insert the fuel injector into the fuel distribution pipe -A- and insert the
clamp on the fuel injector -B - .
5. Insert fuel injectors into the openings in the intake module and press
the fuel gallery down.
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Removing and installing fuel injector Page 7 of 7
Subsequent work
2. Install engine compartment cover at the rear and on the right-hand side. → 700219 Removing and installing
front cover (engine compartment) - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\244019_0.htm 5/19/2011
Removing and installing throttle body Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
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" [9PAAF1 9PAAJ1]→ 243519 Removing and
installing air box for throttle housing (Y-pipe) - section on "Removing" [9PAAE1 9PAAE7]
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Removing and installing throttle body Page 3 of 5
Suction module
1. Pull off cable plug on the throttle housing and pull cable out of the
clip -Arrows- .
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Removing and installing throttle body Page 4 of 5
3. Attach cable plug to throttle housing and insert cable into clip -Arrows- .
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Subsequent work
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" [9PAAF1 9PAAJ1]→ 243519 Removing and installing air
box for throttle housing (Y-pipe) - section on "Installing" [9PAAE1 9PAAE7]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\244219_0.htm 5/19/2011
Removing and installing air flow sensor Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
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Removing and installing air flow sensor Page 3 of 5
Bellows
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4. Pull out retaining clip on the air flow sensor. → Clamp for hot-film
mass air flow meter
5. Pull out air flow sensor.
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.
Bellows
3. Connect electric connector to the air flow sensor.
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Removing and installing air flow sensor Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Checking the intake-air distributor for leaks Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Required tools
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Checking the intake-air distributor for leaks Page 3 of 5
Leak test
Note
The specified description can be used to check the intake system from the air cleaner outlet to the injection
valves for leaks.
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Checking the intake-air distributor for leaks Page 4 of 5
Cylinders must not be located in the overlapping TDC. This happens only if the crankshaft was turned manually.
1. Remove engine compartment cover. → 700219 Removing and installing front cover (engine compartment) -
"Removing" section
Fastening bolts
3. Connect the plugs 9264/7 to the two air cleaner connections and
push in the securing clip.
WARNING
Danger of damaging the intake system if pressure is too high!
Intake system can burst.
Danger of injury from flying components.
→ Do not subject intake system to excessive air pressure (max. 1.2 bar
of absolute pressure).
Plugs on intake manifold
WARNING
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Checking the intake-air distributor for leaks Page 5 of 5
→ Do not pull out the oil dipstick or open the engine during the test procedure.
4. Set compressed-air reducer to 0.2 bar (approx. 1.2 bar absolute pressure).
5. Push a compressed-air hose onto the connection from the plug 9264/7 and connect the other end to the
pressure reducer.
Note
Any leaks that exist between the air cleaner cover and the intake
distributor seal can be located using this method.
9. Push the connections onto the cover of the air cleaner housing and
mount and lock the fastening pins.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing intake-air distributor Page 2 of 12
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove design cover → 108319 Removing and installing engine cover - "Removing" section.
Information
Component overview
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Removing and installing intake-air distributor Page 3 of 12
I - Curved hose
II - Check valve
III - Hose
A - Vacuum line closed
B - Vacuum line closed
Vacuum line
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Suction module
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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ATTENTION
Risk of damaging the fastening bolts!
The fastening bolts will break if they are turned in the wrong
direction.
→ 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. Direction of rotation for fastening bolts
3. Remove the fastening bolts. To do this, take hold of the bolt by the
rubber ring with pliers and pull it out.
Fastening bolts
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.
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.
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Removing and installing intake-air distributor Page 6 of 12
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DANGER
Danger of fire from fuel!
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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!
10. Disconnect fuel line -1- and line -2- to the carbon canister on the radiator tank splash panel.
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
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Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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. Fuel lines
→ Wear a breathing mask with active charcoal filter; do not breathe in
any fuel vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
6. Connect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel.
7. Connect vacuum line to the rear of the intake distributor. The plug must engage audibly.
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Removing and installing intake-air distributor Page 11 of 12
Bellows
ATTENTION
Risk of damaging the fastening bolts!
The fastening bolts will break if they are turned in the wrong
direction.
→ 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. Direction of rotation for fastening bolts
11. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the
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Removing and installing intake-air distributor Page 12 of 12
sheetmetal holder.
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\244619_1.htm 5/19/2011
Removing and installing fuel pressure regulator Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
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)
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Removing and installing fuel pressure regulator Page 3 of 8
Note
If the tank must be opened for emptying, disconnect all connections.
Installation Location:
3. Fold up the retaining brackets of the (right and left) seat-belt buckles. To do so, loosen the four fastening
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Removing and installing fuel pressure regulator Page 4 of 8
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. → Draining and filling fuel
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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. Fuel supply and disconnection points
→ Wear a breathing mask with active charcoal filter; do not breathe in at right connection unit
any fuel vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
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Removing and installing fuel pressure regulator Page 5 of 8
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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.
7. Open the relevant cap with the key T10202 and lift up the connection
unit (cap).
Cap
Information
Component overview
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Removing and installing fuel pressure regulator Page 6 of 8
1. Pull off electric connectors -1 and 2- . Then pull off the fuel lines
-3 and 4- and remove the connection unit (pressure regulator).
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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.
Seal
2. Connect the connection unit. Fit electric connector -1 and 2- and
hose connections -3 and 4- .
3. Place the connection unit into the tank. When doing so, make sure
that the plastic lug is pointing forwards.
Connection unit
Subsequent work
1. Close the tank. To do so, fit the sheetmetal ring and tighten using the
key T10202. → Tightening torque: 104 ftlb.
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Removing and installing fuel pressure regulator Page 8 of 8
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing oxygen sensors in front of catalytic converter Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing oxygen sensors in front of catalytic converter Page 3 of 7
Preliminary work
Preliminary work for removing oxygen sensors in front of catalytic converter - Cayenne S
(M48/00)
1. Remove front wheel → 440519 Removing and installing wheel.
2. Remove front wheel housing liner → 505619 Removing and installing front wheel housing liner - "Removing"
section.
3. Remove engine compartment cover above the oxygen sensor plugs → 700219 Removing and installing front
cover (engine compartment) - "Removing" section.
ATTENTION
Danger of burns from hot exhaust system!
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Removing and installing oxygen sensors in front of catalytic converter Page 4 of 7
6. Release oxygen sensor wire from the cable guide and leave it at the oxygen sensor.
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled NR.96-3
sensors
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled NR.97
sensors
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled assembly
sensors NR.98
→ Special tools - oxygen - Torque wrench, signal-transmitting with changeover ratchet NR.90
sensors
ATTENTION
The oxygen sensor cable can be damaged if twisted!
Change in emissions.
Check Engine light comes on.
→ Always release oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.
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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.
ATTENTION
The oxygen sensor cable can be damaged if twisted!
Change in emissions.
Check Engine light comes on.
→ 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 Oxygen sensor for exhaust manifold
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.
Subsequent work
Touching up for installing oxygen sensors in front of catalytic converter - Cayenne S (M48/00)
1. Push oxygen sensor wire into the cable guide.
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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 → 700219 Removing and installing front cover
(engine compartment) - "Installing" section.
5. Install front wheel housing liner → 505619 Removing and installing front wheel housing liner - "Installing"
section.
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\246919_0.htm 5/19/2011
Removing and installing DME control module Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
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.
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:
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Exhaust-gas standard
ME 7.1.1 min
Type Version Explanation
Low Emission Vehicle, USA
OBD 2 LEV
As of model year '03.
Rest of world
RoW EU2
As of model year '03.
European On-Board
EOBD EU4 Diagnosis.
As of model year '03.
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.
3. Using the →| key, move from the vehicle type to the control modules.
4. Select DME with the cursor keys and press the >> key.
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Removing and installing DME control module Page 4 of 8
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).
ATTENTION
Risk of short circuit!
Note
Unscrew the two fastening screws for the cowl panel cover and lift up the cover in this area. → 664419
Removing and installing cowl panel cover
1. Push the two retaining clips aside -arrows- and remove control unit to
the front.
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Removing and installing DME control module Page 5 of 8
1. Insert both connectors into the control unit and push in latch in
-direction of arrow- .
Note
If a new DME control module is to be installed in a vehicle, the immobiliser 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.
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
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Removing and installing DME control module Page 6 of 8
8. Select emission standard and press >> . → 247019 Removing and installing DME control module -
"Information" section
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 immobiliser code
menu and press >> .
13. Enter the new immobiliser 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.
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
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Removing and installing DME control module Page 7 of 8
(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 immobiliser 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.
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
8. Select emission standard and press >> . → 247019 Removing and installing DME control module -
"Information" section
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 immobiliser code
menu and press >> .
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13. Enter the old immobiliser code (IPAS, vehicle - OLD), continue with the >> key, check the code again and
confirm with F7 .
14. Enter the new immobiliser 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.
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)
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\247019_1.htm 5/19/2011
Removing and installing oxygen sensors behind catalytic converter Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing oxygen sensors behind catalytic converter Page 3 of 7
Preliminary work
ATTENTION
Danger of burns from hot exhaust system!
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Removing and installing oxygen sensors behind catalytic converter Page 4 of 7
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled NR.96-3
sensors
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled NR.97
sensors
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled assembly
sensors NR.98
→ Special tools - oxygen - Torque wrench, signal-transmitting with changeover ratchet NR.90
sensors
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Removing and installing oxygen sensors behind catalytic converter Page 5 of 7
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ATTENTION
The oxygen sensor cable can be damaged if twisted!
Change in emissions.
Check Engine light comes on.
→ Always expose oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.
→ Do not kink cable.
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
1. Install primary catalytic converter→ 267619 Removing and installing primary catalytic converter - "Installing"
section.
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing oxygen sensors behind catalytic converter Page 7 of 7
Mount for primary catalytic converter in Mount for primary catalytic converter in
naturally aspirated engine Turbo
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Checking exhaust system for leaks Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Lift the vehicle. → 40 Lifting the vehicle
Leak test
ATTENTION
Danger of burns from hot exhaust system!
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Checking exhaust system for leaks Page 3 of 4
Note
After the connecting clamps in the exhaust system have been released, they must always be replaced.
During assembly work on the exhaust system, ensure that the components are aligned and installed
correctly.
Note
The exhaust system must be completely sealed between the engine
and the catalytic converters.
5. Remove the plugs and insert the tailpipes into the rear silencer.
Tyre-inflating device on test valve
Subsequent work
Subsequent work
1. Align tailpipes with the bumper and secure them. → 263415 Aligning tailpipes [9PAAD1 9PAAD7 9PAAE1
9PAAE7]→ 263415 Aligning tailpipes [9PAAF1 9PAAJ1]
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Checking exhaust system for leaks Page 4 of 4
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Information
Component information
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Removing and installing exhaust system Page 3 of 6
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Note
The exhaust system in the V6 is designed as a single strand. Repair instructions and notes apply to both exhaust
systems.
WARNING
Danger of burns from hot exhaust system!
WARNING
Danger of injury from heavy exhaust system!
Note
Before the rear silencer is released, the exhaust system must be supported with a transmission jack or held
by another person.
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3. Unscrew the fastening screws on the left and right of the rear
silencer.
4. Install new exhaust clamps. The bolts must be pointing downwards. → Adjustment value: 10 ° →
Tightening torque: 44 ftlb.
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Removing and installing exhaust system Page 6 of 6
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
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Removing and installing exhaust manifold Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Installation Location:
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2. Unclip the oxygen sensor cable from all holders. Remove oxygen
sensor when replacing exhaust manifold.
3. Loosen the 12 fastening nuts in the sequence shown below. Remove
the exhaust manifold.
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Fastening nuts
Note
Visually inspect exhaust manifold for cracks and distortion.
If the studs in the cylinder head are damaged, they must be replaced. → 157356 Replace mount for exhaust
manifold (stud) - "Replacing" section
1. Clean sealing surfaces. The surfaces must be free from foreign objects.
2. Use a new seal. The seal must be positioned so that the part number is visible from the outside.
3. Push the manifold across the studs and fit it with 12 new fastening nuts. The fastening nuts are tightened in
two stages in accordance with the tightening sequence → Tightening sequence for fastening nuts →
Tightening torque: 19 ftlb. and → Tightening torque: 24 ftlb. .
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4. Fit oxygen sensor when replacing exhaust manifold. For details see → 246919 Removing and installing
oxygen sensor ahead of catalytic converter - "Installing" section. Clip oxygen sensor cable into the holders.
5. Fit starting catalytic converters with new gaskets. For details see
→ 267619 Removing and installing primary catalytic converter -
"Installing" section.
Subsequent work
1. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\261019_1.htm 5/19/2011
Checking exhaust system mount Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
ATTENTION
Danger of burns from hot exhaust system!
Note
Check the rubber-metal mounts between the body and the exhaust system for cracks and elongation and
check overall condition.
During the life of the vehicle, the rubber-metal mounts must not soften to such an extent that the exhaust
system starts to hit against adjacent components or the body.
Check the exhaust system for contact with adjacent parts by shaking it manually.
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Examine the metal mount for corrosion and damage and check that it is positioned correctly.
The exhaust system must be moved to the correct installation position or damaged components must be
replaced if necessary.
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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 (of same design as V8)
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
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Checking exhaust system mount Page 6 of 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
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\262801_0.htm 5/19/2011
Replacing rear silencer Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Information
Component overview
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Replacing rear silencer Page 5 of 6
Note
The exhaust system in the V6 is designed as a single strand. Repair
instructions and notes apply to both exhaust systems.
Note
Before the rear silencer is released, the exhaust system must be
supported with a transmission jack or held by another person.
6. Undo the four fastening screws to the left and right on the rear
silencer and remove the rear silencer from the vehicle.
Note
The exhaust system in the V6 is designed as a single strand. Repair instructions and notes apply to both exhaust
systems.
2. Push the two new connecting clamps onto the exhaust pipes on the rear silencer . Then install the rear
silencer using a transmission jack. Tighten the four fastening screws to the specified tightening torque. →
Tightening torque: 17 ftlb.
3. Push connecting clamps over the exhaust system and align them → 263355 Replacing rear muffler -
"Information" section. Tighten fastening screws. → Tightening torque: 44 ftlb.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
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Replacing rear silencer Page 6 of 6
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39,
C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\263355_0.htm 5/19/2011
Adjusting tailpipes Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Adjusting tailpipes
Installation Location:
Overview of tailpipes
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Adjusting tailpipes Page 3 of 4
Component overview
1- Rear muffler
2- 2 mounts (align during installation)
3- 2 tailpipe clamps
4- 2 tailpipes (align during installation)
Aligning tailpipes
3. Tighten bolt on tailpipe clamp. → Tightening torque: 44 ftlb. .
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Adjusting tailpipes Page 4 of 4
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
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Removing and installing tailpipes Page 3 of 4
1- Rear muffler
2- 2 mounts (align during installation)
3- 2 tailpipe clamps
4- 2 tailpipes (align during installation)
1- Rear muffler
2- 2 mounts (align during installation)
3- 2 tailpipe clamps
4- 2 tailpipes (align during installation)
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Removing and installing tailpipes Page 4 of 4
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing secondary air pump Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Installation Location:
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Removing and installing secondary air pump Page 3 of 6
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Component overview
1. Remove hose from secondary air pump. Then separate the electric connector on the secondary air pump.
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Removing and installing secondary air pump Page 5 of 6
Note
On the right secondary air pump also unclip the cooling water hose and vacuum hose.
1. Undo the three fastening screws for the bracket and remove the bracket.
Note
On the right secondary air pump also unclip the cooling water hose and vacuum hose.
1. Install bracket and tighten with the three fastening screws. → Tightening torque: 7.5 ftlb.
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Removing and installing secondary air pump Page 6 of 6
pump
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing (main) catalytic converter Page 2 of 14
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove the engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
ATTENTION
Danger of burns from hot exhaust system
Note
Cover the right wing and guide through a ratchet from above using several extensions in order to loosen the
top nut between the primary and main catalytic converters.
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Note
If the working height of the vehicle has to be changed due to further work, the transmission support must be
re-fitted using the old bolts.
1 - 2 exhaust manifolds
2 - 2 exhaust manifold gaskets (replace during installation)
3 - 24 hexagon nuts M8 (replace during installation; coat threads of studs with Microgleit)
4 - 6 Torx screws M8 x 75
5 - 2 turbocharger gaskets (replace during installation)
6 - 2 oxygen sensors ahead of catalytic converter
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Cayenne S (M48/00)
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Transverse strut
2. Release connecting clamps between catalytic converters and
exhaust system. Then push the clamps backwards onto the exhaust
system. The exhaust clamps must not be reused.
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4. Remove cardan shaft between front-wheel drive and transfer box -see figure- . → 390219 Removing and
installing front cardan shaft - chapter on "removing" [9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and
installing front cardan shaft - chapter on "removing" [9PAAE7]
ATTENTION
Danger of burns from hot exhaust system
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1 - 2 exhaust manifolds
2 - 2 exhaust manifold gaskets (replace during installation)
3 - 24 hexagon nuts M8 (replace during installation; coat threads of studs with Microgleit)
4 - 6 Torx screws M8 x 75
5 - 2 turbocharger gaskets (replace during installation)
6 - 2 oxygen sensors ahead of catalytic converter
7 - 2 gaskets (replace during installation)
8 - 16 hexagon nuts M8
9 - Front catalytic converter
10 - Front catalytic converter
11 - Support
12 - Support
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Cayenne S (M48/00)
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1. Remove transverse strut. Undo the screws -arrows- (do not forget
the centre screw).
Transverse strut
2. Release connecting clamps between catalytic converters and exhaust system. Then push the clamps
backwards onto the exhaust system. The exhaust clamps must not be reused.
3. Release the catalytic converter mounts from the body and cross member (two screws each).
4. Unscrew the three nuts connecting the primary and main catalytic converters and guide out the main
catalytic converter. Remove flange gasket.
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Note
Gaskets and self-locking nuts and bolts must always be replaced!
4. Replace flange gasket and push over the studs of the main catalytic
converter.
6. Tighten nuts connecting primary and main catalytic converters to the specified tightening torque. →
Tightening torque: 17 ftlb.
Note
To fit the cardan shaft, the transmission must be supported again and the transmission support removed.
Then fit the transmission support with new screws. → 390219 Removing and installing front cardan shaft -
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chapter on
"installing" [9PAAE1 9PAAF1
9PAAJ1]→ 390219 Removing
and installing front cardan
shaft - chapter on
"installing" [9PAAE7]
8. Tighten screws of the catalytic converters to the body and cross member with tightening torque. →
Tightening torque: 17 ftlb.
Transverse strut
Installing (main) catalytic converter, cylinder bank 5 - 8
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Transverse strut
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Subsequent work
Subsequent work
1. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove engine compartment cover above the oxygen sensor connectors. → 700219 Removing and
installing front cover (engine compartment) - chapter on "removing"
3. Remove front wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"removing"
4. Remove air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on "removing"
5. Remove main catalytic converter. → 267319 Removing and installing (main) catalytic converter - chapter on
"removing"
ATTENTION
Danger of burns from hot exhaust system
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Note
Observe the most important working regulations and warning notes. → 10 The most important working
regulations and warning notes
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1. At the water splash panel, disconnect the connector for the oxygen
sensor behind catalytic converter and unclip cable from support.
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ATTENTION
Danger of burns from hot exhaust system
Note
Observe the most important working regulations and warning notes. Fastening nuts for securing exhaust
→ 10 The most important working regulations and warning notes manifold to primary catalytic converter
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Removing and installing primary catalytic converter Page 6 of 9
1. At the water splash panel, disconnect the connector for the oxygen
sensor behind catalytic converter and unclip cable from support.
3. Remove the three fastening nuts between the exhaust manifold and primary catalytic converter.
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Installing primary
catalytic converter
Note
Observe the most important working regulations and warning notes. → 10 The most important working
regulations and warning notes
Metal seals and self-locking nuts and bolts must always be replaced!
2. Replace flange gasket and push over the studs of the primary catalytic converter.
4. Through the wheel housing, position fastening screw on catalytic converter bracket.
5. Position the three fastening nuts between the exhaust manifold and
primary catalytic converter.
6. Tighten fastening screw to catalytic converter bracket and nuts to
specified tightening torque. → Tightening torque: 17 ftlb. →
Tightening torque: 17 ftlb.
ATTENTION
Danger of fire and material damage!
→ Lay the oxygen sensor cable so that it cannot touch the exhaust
manifold. Positioning fastening nuts for securing
exhaust manifold to primary catalytic
7. Lay cable of oxygen sensor and clip it in. converter
8. At the water splash panel, connect the connector for the oxygen sensor behind catalytic converter.
Note
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Metal seals and self-locking nuts and bolts must always be replaced!
2. Replace flange gasket and push over the studs of the primary
catalytic converter.
4. Place primary catalytic converter in installation position. Connecting oxygen sensor connector
at water splash panel
5. Position the three fastening nuts between the exhaust manifold and
primary catalytic converter.
ATTENTION
Danger of fire and material damage!
→ Lay the oxygen sensor cable so that it cannot touch the exhaust
manifold. Positioning fastening screw on
catalytic converter bracket
9. At the water splash panel, connect the connector for the oxygen sensor behind catalytic converter.
Subsequent work
Subsequent work
1. Install main catalytic converter. → 267319 Removing and installing (main) catalytic converter - chapter on
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Removing and installing primary catalytic converter Page 9 of 9
"installing"
2. Install air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on "installing"
3. Install front wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
5. Fit engine compartment cover above the oxygen sensor connectors. → 700219 Removing and installing
front cover (engine compartment) - chapter on "installing"
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing battery
Removing battery
Installation Location:
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DANGER
Risk of explosion, injury, short circuit and damage to the generator and electronic control units.
Do not disconnect battery with engine running.
Disconnect and reconnect battery with extreme caution. Risk of short circuit and explosion.
Do not tilt battery when removing it. Risk of acid burns as a result of emerging acid.
Do not rub the battery with a dry cloth. Risk of explosion as a result of static charge.
Note
The battery is located in the battery case under the left front seat.
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The vehicle must be supplied with external power at the jump lead starting points so that the seat can be
moved even when the battery is completely discharged. → External power connection, jump lead starting
Observe the warning notes and safety regulations for lead-acid batteries.→ Warning notes and safety regulations
for lead-acid batteries [9PAAD1 9PAAD7]→ Warning notes and safety regulations for lead-acid
batteries [9PAAE1 9PAAE7 9PAAF1]
Note
For vehicles with a Vehicle Tracking System (VTS), please read the
→ 906323 Vehicle Tracking System (VTS) TI!
1. Move front left seat back and up as far as possible. Move backrest
fully forward.
3. Fold the carpet sections forward and remove the two fastening
screws -1- .
4. Fold the seat back as far as possible -Arrow B- . With the seat in its
folded position, move the seat forward again using the fore-and-aft
adjustment -Arrow C- .
5. Open the four tension hooks on the battery case cover using a
screwdriver.
6. Remove the battery case cover and air duct.
7. Risk of short circuit! First connect the negative cable -2- , then the
positive -3- .
8. Unscrew the fastening screw on the sheetmetal bracket and remove the sheetmetal bracket.
9. Unscrew the screw on the battery mount and remove the battery mount.
10. Pull off the vent hose on the battery.
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Installing battery
Installing battery
1. Risk of contact with caustic fluid Position the battery in the battery
case below the stops, if at all possible without tilting it.
2. Position the battery mount and tighten with the fastening screw. →
Tightening torque: 17.5 ftlb.
Note
Make sure that the two ends of the vent hose are routed and inserted correctly.
5. Risk of short circuit! First connect the positive cable -3- , then the
negative cable -2- . → Tightening torque: 3.5 ftlb.
6. Replace the battery box cover carefully. The cover must be mounted properly.
7. Attach the four tension hooks on the battery case cover and close using the screwdriver.
ATTENTION
Risk of material damage to screw connections for seat and seat frame!
→ 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!
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8. Move the seat in its folded position towards the rear -arrow A- and
then tip forward -arrow B- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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General information on the vehicle battery Page 2 of 13
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
To prevent contact corrosion, only approved bolts, nuts, washers, etc. should be used. These elements have a
special surface coating and must be stored separately.
The battery is one of the most important electrical components in the vehicle. Fault-free functioning of the battery
contributes greatly to customer satisfaction. To guarantee long and efficient operation, the battery must be checked
and maintained according to the description in this chapter.
Besides the start function, the battery also has the tasks of buffer and supplier of electrical power for the entire
vehicle electrical system.
Information
Maintenance-free battery:
Note
The tightening torque for the battery terminals is 5 Nm (3.5 ftlb.).
Low-maintenance battery:
Note
Battery terminals do not need to be greased.
The battery terminal clamps must only be attached manually without using excessive force to prevent damage
to the battery housing.
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To ensure that the battery does not leak, it is essential to ensure that the original plugs supplied with the
battery are screwed into the battery openings.
In the event of loss or damage, only original plugs of the same design should be used.
Note
First aid: Rinse acid splashes in the eyes immediately with clean water for a few minutes. Consult a doctor
immediately. Neutralise acid splashes on the skin or clothing immediately with soap suds and rinse again with
plenty of water. If acid has been drunk unintentionally, consult a doctor immediately.
5. -5- Observe information on the battery in the Technical Manual and in the Driver's Manual.
Note
The battery is located under the left front seat.
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In order to avoid triggering the siren in vehicles with an additional alarm siren, the battery must be
disconnected while the ignition is on!
The battery terminal clamps must only be attached by hand without using excessive force to prevent damage
to the battery housing.
Check that the battery is seated correctly after installation. Otherwise, a loose battery presents risks such as: -
Reduced service life due to vibration damage. - Possible damage to the grid plates of the battery. - Damage to
the battery housing from mounting parts (possible acid leakage, with high subsequent costs). - Inadequate
crash safety.
Note
State of the art batteries are fitted with central venting -A- .
Central venting
In batteries with hose/pipe -A- for the central venting, ensure that the
hose is not pinched. Only then can the battery be freely vented.
Central venting
Visual inspection
Before measurements such as open-circuit voltage, acid density or the battery load test are carried out, a visual
inspection of the battery must be performed.
Whether the housing of the battery is damaged. Acid can leak out due to damage of the housing.
Whether the battery terminals (battery line connections) are damaged. Contact of the line connections cannot
be guaranteed if the battery terminals are damaged. This can cause a line fire and malfunctions in the
electrical system.
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Note
Make sure the vent hose -A- is not kinked or damaged. If in doubt, replace it.
Vent hose -A- must be inserted in the battery and in the battery box.
Central venting
Checking acid level
1. Switch ignition off and remove ignition key.
2. Move front left seat back and up as far as possible. Move backrest
fully forward.
4. Fold the carpet cut-outs forwards and remove the two fastening
screws -Arrows 1- .
5. Fold the seat back completely -Arrow B- . With the seat in its folded
position, move the seat forward again using the fore-and-aft
adjustment -Arrow C- .
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WARNING
Improper handling of batteries.
Risk of injury and damage to the environment
→ The accident prevention regulations must be strictly observed when handling battery acids.
→ Wear suitable protective clothing and protective glasses.
→ Only use a torch to illuminate the inside of the battery. Never illuminate the inside of the battery with a naked
flame.
→ Do not handle a naked flame or lighted cigarettes near batteries.
→ Observe the disposal regulations for batteries and sulphuric acid when disposing of batteries.
Note
Use a commercially available battery filling bottle.
The correct acid level of the battery is an important factor for long and efficient operation of the battery.
When the acid level is too low, a capacity loss (performance loss) of the battery occurs, which is caused by
the cell plates drying out. If the cell plates are not surrounded by electrolyte (battery acid), this will lead to
corrosion of the lead plates, the plate bridges and the cell connectors. The result of the corrosion is that
battery functioning cannot be guaranteed. The battery will become unserviceable.
If the acid level is too high, damage can occur by the battery acid (sulphuric acid/water mixture) leaking out of
the battery.
2. Shine a torch into the battery. The acid level of the battery must be at the protruding lug.
– If the acid level is too low, refill with distilled water using the battery filling bottle.
3. Screw in battery plugs again and ensure that they are seated correctly.
Maintenance-free battery
Note
The maintenance-free battery has an inspection glass.
The charge state and acid level of the battery can be checked through the inspection glass -B- .
If a battery is more than 5 years old and the indicator of the inspection glass is colourless, replace the battery.
If the battery has been charged, air bubbles can form under the inspection glass. Before carrying out a visual
inspection, tap carefully on the inspection glass with something like the handle of a screwdriver.
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Maintenance-free battery
Three different colour indications are possible:
Maintenance-free battery
Colour indication Charge state
Green The battery charge is satisfactory.
Battery will start reliably.
Dark grey The battery has no charge or the charge is too low.
Recharge battery.
Transparent/clear Acid level has become critical.
Replace battery.
WARNING
Improper handling of batteries.
Risk of injury and damage to the environment
→ The accident prevention regulations must be strictly observed when handling battery acids.
→ Wear suitable protective clothing and protective glasses.
→ Only use a torch to illuminate the inside of the battery. Never illuminate the inside of the battery with a naked
flame.
→ Do not handle a naked flame or lighted cigarettes near batteries.
→ Observe the disposal regulations for batteries and sulphuric acid when disposing of batteries.
Note
Only for low-maintenance batteries.
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Note
Use commercially available battery acid tester.
The acid density test provides information about the state of the battery in conjunction with the battery load
test.
The density of the acid must be checked as follows in all battery cells (low-maintenance battery) :
3. Dip the acid siphon or the pipette into the battery cell and take up the battery acid.
4. Read off the density of the acid in kg/dm³ on the scale of the battery acid tester and compare with the
following table.
Battery charge state in tropical climatic zones (hot countries) Density in kg/dm³
discharged 1.08
half charged 1.16
well charged 1.23
The acid density must be at least 1.24 kg/dm³ in normal climatic zones.
The measured values for the acid density of the individual battery cells must not differ by more than 0.03 kg/dm³
from each other.
Example 2: The acid density in cells 4 and 5 is too low. The acid density deviations between the battery cells is
greater than 0.03 kg/dm³.
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– If the nominal values are achieved, screw in the original plugs again.
ATTENTION
Risk of material damage to screw connections for seat and seat frame!
→ 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!
5. Move the seat in its folded position towards the rear -Arrow A- and
then tip forward -Arrow B- .
Note
Use a hand-held multimeter to measure the battery voltage.
Note
After charging and waiting for at least 2 hours, during which time the battery should neither be loaded nor
charged:
– If the hand-held multimeter shows 12.5V or more, the battery voltage is OK.
– If the hand-held multimeter shows a battery voltage below 12.5V: Charge battery.
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Note
The acid density test provides information about the state of the battery in conjunction with the battery load
test.
2. Observe the information in the operating instructions of the battery test device.
3. Connect the clamps of the test lines to the battery terminals as described in the operating instructions of the
test device.
– As the load current varies, the current must be set depending on the battery capacity (operating instructions of
test device).
4. Perform the battery load test in accordance with the operating instructions.
– The result of the battery load test is a voltage value that must be compared with the specified minimum
voltage (limit value).
Table:
Battery capacity: 70 Ah 95 Ah 110 Ah
Cold test current 340 A 450 A 520 A
Load current See tester instructions
Minimum voltage (limit value) See tester instructions
The battery voltage sinks during this test due to the severe load on the battery.
If the battery is in order, the voltage value only decreases to the minimum voltage.
If the battery is faulty, the battery voltage will sink very quickly below the specified minimum voltage.
After the test has taken place, the low voltage value remains over a long period of time; the voltage increases
again slowly.
Charging battery
WARNING
Danger of fire and explosion
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→ The battery plugs must always be screwed in correctly when charging and during voltage measurement and
load measurement.
→ Rooms in which batteries are being charged should not be entered with a naked flame or when smoking.
Gases form through the charging process in the batteries which are highly flammable.
Note
A battery charging device is required.
If exhaustively discharged batteries are charged quickly, they will not take up a charge current or they will be
identified too early as full due to the so-called "surface charge".
3. First disconnect the ground strap of the battery, then the positive battery line.
4. Connect positive line of the battery charging device to the positive terminal of the battery.
5. Connect negative line of the battery charging device to the negative terminal of the battery.
6. Set the charge current on the battery charging device according to the battery capacity.
Batteries which are not in operation for a long period of time discharge.
A battery is exhaustively discharged if the open-circuit voltage has sunk below 11.6 V.see open-circuit voltage
measurement
In exhaustively discharged batteries, the battery acid (sulphuric acid and water mixture) consists of virtually only
water, as the sulphuric acid proportion is considerably reduced.
Exhaustively discharged batteries sulphatise, i.e. the entire plate surfaces of the batteries harden.
If exhaustively discharged batteries are immediately recharged after an exhaustive discharge, the sulphatisation
recedes again.
If these batteries are not recharged, the plates continue to harden and charge take-up ability is limited. A reduction
in the battery performance is the result.
Exhaustively discharged batteries must be charged with a low charge current as follows:
– Set maximum charge current at 10% of battery capacity; i.e. with a 95 Ah battery the maximum charge current
is 9.5 A.
8. Charge battery.
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Note
When working or carrying out tests on the Cayenne, or when it is in the workshop, a battery charging device
with a rated current of at least 40 A must be connected.
As soon as the vehicle is unlocked, e.g. the vehicle is in the workshop or salesroom, it must be trickle charged
with a battery charging device.
5. First, connect the positive cable from the charging device to the
positive terminal for jump lead starting -+- . → Tightening torque: 3.5
ftlb.
6. Connect the negative cable from the charging device to the ground
point for jump lead starting - - - . → Tightening torque: 3.5 ftlb.
7. Set the charge current on the battery charging device according to the
battery capacity.
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A suitable battery charging device must be connected to the vehicle electrical system when performing the
following tasks. All unnecessary loads must be switched off.
If the doors, bonnet and rear lid are open for a long period of time or if these components are actuated frequently
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
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.
Installation Location:
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DANGER
Risk of explosion, injury, short circuit and damage to the generator and electronic control units.
2. Observe the warning notes and safety regulations for hydrocyanic acid batteries → 2706 Battery
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7.1. Risk of short circuit! First disconnect the negative cable -arrow 1- , then the positive cable -arrow 2- .
7.3. Unscrew the battery mount nut and remove the retaining bracket for the battery mount -arrow 5- .
7.4. Risk of causticisation! Remove battery from the battery case by the folding handles, if at all possible
without tilting it.
1.1. Risk of causticisation! Position the battery in the battery case below
the stops, if at all possible without tilting it.
1.2. Position retaining bracket and tighten with fastening nut -arrow 5- .
→ Tightening torque: 17 ftlb.
Note
Make sure that the two ends of the vent hose are routed and inserted
correctly.
1.4. Risk of short circuit! First connect the positive cable -arrow 1- ,
then the negative cable -arrow 2- . → Tightening torque: 3.5 ftlb.
2.1. Put on the battery case cover, position it and clip in the four fastening clips -arrows A- onto the cover.
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3. Install subwoofer:
3.2. Push the electrical plug connection together until the plug is felt to
engage.
Installing subwoofer
Note
If the vehicle contains a subwoofer or collapsible spare wheel the
relevant component must be re-installed.
4. Fastening subwoofer:
4.1. Insert fastening screw -3- with washer and tighten. → Tightening
torque: 3.5 ftlb.
4.2. Position both fastening nuts -2- and tighten them. → Tightening
torque: 1.5 ftlb. Mount for subwoofer
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
Preliminary work
1. Before the three-phase generator can be removed, the battery must be disconnected and the terminal
covered. → 90 Work instructions after disconnecting the battery
2. Remove right wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"removing"
3. Remove right air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on
"removing"
4. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
5. Drain coolant . → 193817 Draining and filling in coolant (includes bleeding) - chapter on "draining"
6. Remove drive belt. → 137819 Removing and installing drive belt - chapter on "removing"
Note
When the engine is being cleaned with high-pressure cleaning equipment, make sure that the high pressure
blast is not directed directly onto the three-phase generator (risk of bearing damage).
Installation Location:
Note
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If the impact bracket is used, the routing of the wires may differ from
this description!
1. Unscrew the three fastening screws -8- for the impact bracket and
remove the impact bracket.
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Note
If the protective cap cannot be removed, use a knife to carefully cut if
off the three-phase generator. Make sure that the plug connection
and the electrical lead are not damaged and that there is no more
than minimal damage to the protective cap.
6. Pull off protective cap for electrical plug connection from receptacle
on three-phase generator.
Note
Additional assembly operations must be performed if a new three-phase generator has to be fitted. → 272219
Removing and installing new three-phase generator - chapter on "completing"
1. Insert the three-phase generator through the opening - wheel housing liner with air-cleaner box removed -
-Arrow A- and position it on the engine -Arrow B- .
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2. Position the three fastening screws -1 and 2- and tighten them. → Tightening torque: 17 ftlb.
3. Additional assembly operations must be performed if a new three-phase generator has to be fitted.
4. Insert the plug -6- until the locking tab -A- is felt to engage.
Note
Check condition of protective cap; if it is damaged it must be repaired
using body sealant.
7. Position protective cap and press it on, ensuring it fits securely and is
sealed against moisture.
10. Secure ground lead to three-phase generator with fastening screw -3- . → Tightening torque: 15 ftlb.
11. Attach clip -4- of the electrical lead to the three-phase generator.
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12. Position the impact bracket and screw into place with the fastening screws -8- . → Tightening torque: 7.5
ftlb.
Note
The parts pack of a new three-phase generator contains all the parts required (insulator, PIN and socket).
1. Lay the lead of the new three-phase generator as for the old lead and
clip into the three retaining clips -Arrows A- .
2. Trim the lead (with 2-pole plug) included in the engine wiring harness
to the three-phase generator -arrow- such that, together with the
new lead already laid from the three-phase generator, it can be
joined without tension and without too much slack.
3. In the wiring harness, insulate and immobilise the wire to PIN 2 of the
plug that was cut off.
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4. In the wiring harness, remove the insulation of the wire to PIN 1 of the plug that was cut off and push new
insulator -1- onto the wire.
5. Crimp new PIN -2- using repair kit for wiring harnesses NR.155-1 and repair kit for Cayenne wiring
harnesses NR.155-2 .
6. Insert wire with new PIN into the new socket -3- and lock.
8. Tie the plug connection with a tie-wrap -2- to the nearby wiring
harness.
Subsequent work
Subsequent work
1. Install drive belt. → 137819 Removing and installing drive belt - chapter on "installing"
2. Fill in coolant. → 193817 Draining and filling in coolant (includes bleeding) - chapter on "filling in"
3. Install right air-cleaner box. → 242519 Removing and installing air cleaner housing - chapter on "installing"
4. Install right wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
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5. Connect the battery and carry out the work instructions. → 90 Work instructions after disconnecting the
battery
6. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Before the generator can be removed, the battery must be disconnected and the terminal covered. → 90
Work instructions after disconnecting the battery
2. Remove right front wheel.→ 440519 Removing and installing wheel - section on "Removing"
3. Remove right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section on
"Removing"
4. Remove right air cleaner housing. → 242519 Removing and installing air cleaner housing - section on
"Removing"
5. Remove engine guard. → 108019 Removing and installing engine guard - section on "Removing"
6. Drain coolant. → 193817 Draining and filling in coolant (includes bleeding) - section on "Draining"
7. Remove drive belt. → 137819 Removing and installing drive belt - section on "Removing"
Note
This description applies to engine numbers as of M48/00 816 09867.
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Note
When the engine is being cleaned with high-pressure cleaning equipment, make sure that the high pressure
blast is not directed directly onto the three-phase generator (risk of bearing damage).
Installation Location:
Overview of generator
1. Unscrew the three fastening screws -8- for the impact bracket and
remove the impact bracket.
3. Lever out fastening clips -4- for the electric line using a screwdriver.
4. Seal the coolant hoses -A and B- with a hose clamp to prevent them from leaking.
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Sealing coolant hoses with hose clip Unscrewing fastening screw on ground
lead.
7. Unscrew fastening screw -2- on the heat protection shield for generator lines.
8. Unscrew fastening nut -5- on the B+ line. Unclip the B+ line at the
two retaining clips -6- and remove it.
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13. Remove the generator through the opening – wheel housing liner
with air-cleaner box removed.
1. Insert the generator through the opening - wheel housing liner with air-cleaner box removed - -Arrow A- and
position it on the engine -Arrow B- .
2. Position the three fastening screws -1 and 2- and tighten them. → Tightening torque: 23 (17 ftlb.) Nm
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5. Secure the heat protection shield with the generator lines to the
generator using the fastening screw -2- . → Tightening torque: 10
(7.5 ftlb.) Nm
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8.1. Grease the new seal on the supply connection piece -1- with
Vaseline.
8.2. Press supply connection piece -1- as far as it will go into the supply
coolant bore on the generator and secure with the new fastening
screw -2- . → Tightening torque: 10 (7.5 ftlb.) Nm
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Subsequent work
Subsequent work
1. Install drive belt. → 137819 Removing and installing drive belt - section on "Installing"
2. Fill in coolant. → 193817 Draining and filling in coolant (includes bleeding) - section on "Filling in"
3. Install right air cleaner housing. → 242519 Removing and installing air cleaner housing - section on
"Installing"
4. Install right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section on
"Installing"
5. Fit right front wheel. → 440519 Removing and installing wheel - section on "Installing"
6. Connect the battery and carry out the work instructions. → 90 Work instructions after disconnecting the
battery
7. Fit engine guard. → 108019 Removing and installing engine guard - section on "Installing"
9PAAE1, 9PAAE7
as of MY 2006
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
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Preliminary work
1. Before the generator can be removed, the battery must be disconnected and the terminal covered. → 90
Work instructions after disconnecting the battery
2. Remove right front wheel.→ 440519 Removing and installing wheel - section on "Removing"
3. Remove right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section on
"Removing"
4. Remove right air cleaner housing. → 242519 Removing and installing air cleaner housing - section on
"Removing"
5. Remove engine guard. → 108019 Removing and installing engine guard - section on "Removing"
6. Drain coolant. → 193817 Draining and filling in coolant (includes bleeding) - section on "Draining"
7. Remove drive belt. → 137819 Removing and installing drive belt - section on "Removing"
Note
This description applies to engine numbers up to M48/00 816 09866.
When the engine is being cleaned with high-pressure cleaning equipment, make sure that the high pressure
blast is not directed directly onto the three-phase generator (risk of bearing damage).
Installation Location:
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Overview of generator
1. Unscrew the three fastening screws -8- for the impact bracket and
remove the impact bracket.
3. Lever out fastening clips -4- for the electric line using a screwdriver.
6. Cut off the electric line directly behind the protection cap -Arrow- on the generator.
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9. Unscrew the three fastening screws -1 and 2- and support the generator with your hand.
10. Remove the generator through the opening – wheel housing liner with air-cleaner box removed.
Note
The following parts are required for installing the Hitachi generator.
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1- Generator
2- Return connection piece
3- Supply connection piece
4- 3x screw, M6 x 16
5- 1x hose clamp
6- Heat protection shield
7- 1x screw, M6 x 12
8- 1x line
9- 1x connector
10 - 1x shrink-fit hose
11 - 1x cable connection
Parts -8 to 11- are included in the Repair kit for Cayenne wire harnesses NR.155-2.
1.1. Pull off both caps for the coolant bores -2- on the new generator -1- ( -Arrows A- ).
1.2. Grease the seal -3- on the new return connection piece -4- with Vaseline.
1.3. Press return connection piece -4- as far as it will go into the return coolant bore on the new generator -1- (
-Arrow B- ) and secure with the new fastening screw -5- . → Tightening torque: 10 (7.5 ftlb.) Nm
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6.1. Press hose clamp -2- together and pull supply connection piece -1- out of the coolant hose.
7.1. Grease the seal -2- on the new supply connection piece -1- with
Vaseline.
7.2. Press supply connection piece -1- as far as it will go into the supply
coolant bore on the new generator -Arrow A- and secure with the
new fastening screw -3- . → Tightening torque: 10 (7.5 ftlb.) Nm
7.3. Fit the coolant hose -4- with a new hose clamp -5- and push it onto
the supply connection piece -1- ( -Arrow B- ).
9.1. Push new line -1- with the PIN fully into the connector housing -2- ( -Arrow A- ).
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Note
Select a place for the joint where there is enough space to join all the lines present.
Do not cut the lines too short in case they have to be laid in a different position if there is insufficient space in the
area of the joint.
Note
The electric lines are located in the splash water area and are thus exposed to the highest demands.
The greatest care must be taken in the individual work steps for stripping insulation from, crimping, and
shrinking/insulating the electric lines.
The procedure for stripping insulation from, crimping, and shrinking/insulating the electric lines must be complied
with and observed. The procedures are described in detail in the Repair kit for Cayenne wire harnesses
NR.155-2.
Note
Allocation of lines - see wiring diagram.
10. Crimp the line from the new generator -1- with the line from the engine wire harness -4- .
10.1. Trim the line from the engine wire harness -4- so that it can be joined to the new line that was already laid
from the generator -1- without tension and without too much slack.
10.2. In the engine wire harness -4- , insulate and immobilise the wire to PIN 2 of the connector that was cut off.
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10.3. In the engine wire harness -4- , strip 10 mm of the line to PIN 1 of the connector that was cut off and push
new shrink-fit hose -3- onto the line.
10.4. Crimp both lines -1 and 4- using a new crimping sleeve -2- and the hand crimping pliers from the Repair
kit for wire harnesses NR.155-1.
10.5. Slide new shrink-fit hose -3- over the crimp connection and carefully shrink it to make it watertight using the
hot-air blower with special nozzle (recommended accessories for the repair kit for wire harnesses).
11. Wrap commercially available PVC tape all around the area of the connection point.
12. Push the plug connection -1- together until it is felt to engage.
13. Secure wire harness -2- to the wire harness running parallel using
two tie-wraps -3- .
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Subsequent work
Subsequent work
1. Install drive belt. → 137819 Removing and installing drive belt - section on "Installing"
2. Fill in coolant. → 193817 Draining and filling in coolant (includes bleeding) - section on "Filling in"
3. Install right air cleaner housing. → 242519 Removing and installing air cleaner housing - section on
"Installing"
4. Install right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section on
"Installing"
5. Fit right front wheel. → 440519 Removing and installing wheel - section on "Installing"
6. Connect the battery and carry out the work instructions. → 90 Work instructions after disconnecting the
battery
7. Fit engine guard. → 108019 Removing and installing engine guard - section on "Installing"
9PAAE1, 9PAAE7
as of MY 2006
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\272255_1.htm 5/19/2011
Removing and installing starter Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Removing"
2. Disconnect battery. → 270619 Removing and reinstalling battery - chapter on "Removing"; → 90 Work
instructions after disconnecting the battery
WARNING
Risk of damage to starter
Installation Location:
file://E:\POSES\data\rl\2\9PA\276019_1.htm 5/19/2011
Removing and installing starter Page 3 of 5
Overview of starter
1. Unscrew fastening nuts -1- and -2- on the starter, remove the lines
and lay them to one side.
Fastening screws
3. Pull starter forward in the direction of travel -arrow A- , turn slightly -arrow B- and remove in an upward
direction -arrow C- .
file://E:\POSES\data\rl\2\9PA\276019_1.htm 5/19/2011
Removing and installing starter Page 4 of 5
Subsequent work
Subsequent work
1. Install intake distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on "Installing"
2. Connect the battery . → 270619 Removing and reinstalling battery - chapter on "Installing"; → 90 Work
instructions after disconnecting the battery
file://E:\POSES\data\rl\2\9PA\276019_1.htm 5/19/2011
Removing and installing starter Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\276019_1.htm 5/19/2011
External power connection, jump lead starting Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Note
If the battery is flat, jump leads can be used together with the battery of another vehicle to start the car or to
supply external power to the vehicle.
The capacity (Ah) of the battery supplying the power must not be significantly lower than that of the flat battery.
WARNING
Risk of damage and injury as a result of a short circuit.
→ Use only standard jump leads with a sufficiently wide cross section and fully insulated terminal clamps.
Observe the cable manufacturer's specifications.
→ Route the jump leads so that they cannot become entangled in moving parts in the engine compartment.
→ No contact is allowed between the vehicles, otherwise electricity could flow as soon as the positive terminal
is connected.
The flat battery must be properly connected to the vehicle electrical system.
2. Open protective cover on the positive terminal -+- for jump lead starting -arrow A- .
3. Connect the positive cable to the positive terminal for jump-lead starting -+- , then to the positive terminal of
the battery supplying the power.
4. First, connect the negative cable to the negative terminal of the battery supplying the power, then to the
ground point for jump-lead starting - - - .
file://E:\POSES\data\rl\2\9PA\4611234_Tkt_0.htm 5/19/2011
External power connection, jump lead starting Page 3 of 3
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\4611234_Tkt_0.htm 5/19/2011
Removing and installing ignition switch Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
Installation Location:
file://E:\POSES\data\rl\2\9PA\280419_1.htm 5/19/2011
Removing and installing ignition switch Page 3 of 6
1. Carefully lift rubber sleeve on the ignition starter switch -arrow A- using a screwdriver, for example, and
remove it.
2. Carefully unclip moulding for dashboard -arrow B- with a plastic spatula. Observe the two upper lugs when
doing do.
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.
5. Press connector -arrow- and pull off from ignition starter switch.
file://E:\POSES\data\rl\2\9PA\280419_1.htm 5/19/2011
Removing and installing ignition switch Page 4 of 6
Union nut
Installing ignition switch
4. Position moulding and press onto the dashboard until the clips engage.
file://E:\POSES\data\rl\2\9PA\280419_1.htm 5/19/2011
Removing and installing ignition switch Page 5 of 6
Subsequent work
Subsequent work
1. Install cover under instrument panel on left. → 702219 Removing and reinstalling cover under dashboard -
chapter on "Installing"
Information
Note
In the event of insufficient or non-existent battery positive voltage, the ignition key can be removed using the
emergency operation.
1. Push a ball-point pen, for example, into the opening next to the key,
turn the ignition key to position 0 and pull out.
Ignition key
2. Key in position 0, press release -arrow- and pull key out.
file://E:\POSES\data\rl\2\9PA\280419_1.htm 5/19/2011
Removing and installing ignition switch Page 6 of 6
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\280419_1.htm 5/19/2011
Replacing ignition coils Page 2 of 9
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Switch ignition off and remove ignition key
2. Remove engine compartment cover on the right and rear. → 700219 Removing and reinstalling front cover
(engine compartment) - chapter on "Removing"
3. Loosen the secondary air pump from cylinder row 1-4. To do this, unscrew the 3 fastening screws, pull the
file://E:\POSES\data\rl\2\9PA\282055_0.htm 5/19/2011
Replacing ignition coils Page 3 of 9
Note
Place a cloth between design cover and support for secondary air
pump to avoid scratching cover.
file://E:\POSES\data\rl\2\9PA\282055_0.htm 5/19/2011
Replacing ignition coils Page 4 of 9
7. Remove torque support bracket. To do so, undo the 4 fastening screws and set bracket aside.
Ignition coil
file://E:\POSES\data\rl\2\9PA\282055_0.htm 5/19/2011
Replacing ignition coils Page 5 of 9
11. Reconnect the new ignition coil. Tighten the fastening screws. →
Tightening torque: 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.
Install cover
15. Press down the two rubber mountings on the support. The rubber mountings must be felt to engage.
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Replacing ignition coils Page 6 of 9
16. Tighten the four fastening screws on the ignition coils (illustration shows side 5-8). → Tightening torque:
3.5 ftlb.
19. Tighten torque support fastening screw on the body (M10 x 70) . →
Tightening torque: 44 ftlb.
Note
A rag should be placed between the secondary air pump and the design cover to prevent the cover from
being scratched.
file://E:\POSES\data\rl\2\9PA\282055_0.htm 5/19/2011
Replacing ignition coils Page 7 of 9
Design cover of cylinder bank 5-8 Fastening screws on ignition coil cover
3. Lift the front of the design cover and remove it.
7. Reconnect a new ignition coil. Tighten the fastening screws. → Tightening torque: 7.5 ftlb.
file://E:\POSES\data\rl\2\9PA\282055_0.htm 5/19/2011
Replacing ignition coils Page 8 of 9
Fastening screws for ignition coil Pulling the ignition coil out and
replacing it
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.
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Replacing ignition coils Page 9 of 9
Subsequent work
1. Install engine compartment cover on the right and rear. → 700219 Removing and reinstalling front cover
(engine compartment) - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\282055_0.htm 5/19/2011
Removing and installing hall sender Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Removing"
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.
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.
file://E:\POSES\data\rl\2\9PA\283919_0.htm 5/19/2011
Removing and installing hall sender Page 3 of 3
1. Push the hall sender into the camshaft housing and tighten the
fastening screw. → Tightening torque: 7.5 ftlb.
Subsequent work
Subsequent work
1. Install intake distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\283919_0.htm 5/19/2011
Replacing spark plugs Page 2 of 10
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Switch off ignition and remove ignition key.
file://E:\POSES\data\rl\2\9PA\287055_1.htm 5/19/2011
Replacing spark plugs Page 3 of 10
Note
Place a cloth between design cover and support for secondary air
pump to avoid scratching cover.
file://E:\POSES\data\rl\2\9PA\287055_1.htm 5/19/2011
Replacing spark plugs Page 4 of 10
coil cover
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.
Removing cover
8. Remove torque arm bracket. To do so, undo the four fastening
screws and set bracket aside.
Note
Place a cloth between secondary air pump and design cover to avoid scratching the cover.
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Replacing spark plugs Page 5 of 10
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.
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.
5. Undo spark plugs using special tool spark plug wrench 3122 B
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Replacing spark plugs Page 6 of 10
ATTENTION
Broken spark plug electrodes can damage the engine!
Bits of electrodes can fall into the combustion chamber.
→ Only check electrode gap of spark plugs, but do not bend them.
→ Spark plugs with an incorrect electrode gap must be replaced.
file://E:\POSES\data\rl\2\9PA\287055_1.htm 5/19/2011
Replacing spark plugs Page 7 of 10
Note
Use only spark plugs approved by Porsche AG!
8.
Tighten spark plugs using special tool spark plug wrench 3122 B.
→ Tightening torque: 25 (19 ftlb.) Nm , → Tightening torque: 30
(22 ftlb.) Nm
Tightening spark plugs using spark
plug wrench
9. Reconnect the ignition coil. Tighten the fastening screws. →
Tightening torque: 10 (7.5 ftlb.) Nm
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.
file://E:\POSES\data\rl\2\9PA\287055_1.htm 5/19/2011
Replacing spark plugs Page 8 of 10
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 (centre of valve cover) the M6 x
40 are first tightened to → Initial tightening: 3.5 ftlb. and then to →
Final tightening: 7.5 ftlb. .
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:
file://E:\POSES\data\rl\2\9PA\287055_1.htm 5/19/2011
Replacing spark plugs Page 9 of 10
3.5 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. → 700219 Removing and installing front cover
(engine compartment) - chapter on "installing"
file://E:\POSES\data\rl\2\9PA\287055_1.htm 5/19/2011
Replacing spark plugs Page 10 of 10
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\287055_1.htm 5/19/2011
Removing and installing knock sensor Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Removing"
2. Remove and fold up cover for coolant regulator (thermostat). → 195819 Removing and installing coolant
regulator (thermostat) - chapter on "Removing"
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.
file://E:\POSES\data\rl\2\9PA\287219_0.htm 5/19/2011
Removing and installing knock sensor Page 3 of 4
Note
The knock sensor and the cable plug must be aligned so that they never touch!
ATTENTION
Engine damage and changed exhaust behaviour due to incorrectly
mounted knock sensors!
Subsequent work
Subsequent work
1. Install cover for coolant regulator (thermostat). → 195819 Removing and installing coolant regulator
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Removing and installing knock sensor Page 4 of 4
2. Install intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Installing"
3. Fill and bleed the cooling system. → 193817 Draining and filling coolant (includes bleeding) - chapter on
"Filling"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\287219_0.htm 5/19/2011
Checking fuel pressure Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
file://C:\POSES\data\rl\2\9PA\200201_0.htm 17.08.2011
Checking fuel pressure Page 3 of 6
Special tools
file://C:\POSES\data\rl\2\9PA\200201_0.htm 17.08.2011
Checking fuel pressure Page 4 of 6
Special tools
Information
Test conditions
file://C:\POSES\data\rl\2\9PA\200201_0.htm 17.08.2011
Checking fuel pressure Page 5 of 6
Design cover
3. Connect connection line 9559 to the pressure gauge p378 .
Screw the other end onto the fuel gallery.
Connection line
4. Switch on the ignition and start the engine. Read off fuel pressure
on pressure gauge. The value must be 4.0 ± 0.2 bar at idle
speed.
Pressure gauge
DANGER
Danger of fire due to incorrect or faulty scavenging valves!
Note
The steady-state pressure must be greater than 2.0 bar after 1 hour.
5. Unscrew connection line and close the fuel gallery with a new plastic cap.
file://C:\POSES\data\rl\2\9PA\200201_0.htm 17.08.2011
Checking fuel pressure Page 6 of 6
6. Press the 4 rubber elements in the cover onto the 4 ball head
supports. The mounts must be felt to engage.
Design cover
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\200201_0.htm 17.08.2011
Removing fuel tank Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
file://C:\POSES\data\rl\2\9PA\201021_0.htm 17.08.2011
Removing fuel tank Page 3 of 8
2. Remove the carbon canister. Details for loosening in installation location (wheel housing) see → 202521
Removing carbon canister. The degassing tank is removed with the fuel tank connected (joined).
3. Remove rear axle (spring struts and rear axle housing) push it aside on the lifting platform (scope of work
without further disassembly of rear axle) → 420519 Removing and installing rear axle housing - chapter
on "Removing"
Required tools
DANGER
Danger of poisoning from fuels!
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Removing fuel tank Page 4 of 8
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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Removing fuel tank Page 5 of 8
Note
The repair procedure may vary depending on engine type and country equipment. This relates in
particular to components in the right wheel housing.
The following exploded drawing shows how the fuel tank is attached to the vehicle floor.
file://C:\POSES\data\rl\2\9PA\201021_0.htm 17.08.2011
Removing fuel tank Page 6 of 8
file://C:\POSES\data\rl\2\9PA\201021_0.htm 17.08.2011
Removing fuel tank Page 7 of 8
2. Screw the tank cap down. Then remove the rubber sleeve
around the fuel filler neck, loosen the two fastening screws M6 x
25 and remove the ground cable.
Connection unit
4. Pull fuel filler neck and degassing tank out of the wheel housing
and secure with a piece of wire arrow -arrow- (picture shows
degassing tank with carbon canister).
6. Remove line holder under the stone shield by pressing on the centre plug -arrow- . Replace holder.
7. Remove the centre underbody cover at the left and right of the longitudinal side members. → 519319
Removing and installing centre cover - chapter on "removing"
8. Remove rear heat shield. To do so, undo the three speed nuts and the two screws.
file://C:\POSES\data\rl\2\9PA\201021_0.htm 17.08.2011
Removing fuel tank Page 8 of 8
DANGER
Danger of injury due to
heavy filled tank!
ATTENTION
Risk of damaging to fuel lines!
Lines can become kinked or can crack.
10. Undo and remove the remaining restraining straps with the help Tank on lever
of a second worker. Slowly lower the tank with the transmission
jack. Also carefully guide the degassing tank in the right wheel
housing.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\201021_0.htm 17.08.2011
Installing fuel tank Page 2 of 9
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Required tools
file://C:\POSES\data\rl\2\9PA\201023_0.htm 17.08.2011
Installing fuel tank Page 3 of 9
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
file://C:\POSES\data\rl\2\9PA\201023_0.htm 17.08.2011
Installing fuel tank Page 4 of 9
DANGER
Danger of fire from fuel!
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
Note
The repair procedure may vary depending on engine type and country equipment. This relates in
particular to components in the right wheel housing.
file://C:\POSES\data\rl\2\9PA\201023_0.htm 17.08.2011
Installing fuel tank Page 5 of 9
The following exploded drawing shows how the fuel tank is attached to the vehicle floor.
file://C:\POSES\data\rl\2\9PA\201023_0.htm 17.08.2011
Installing fuel tank Page 6 of 9
file://C:\POSES\data\rl\2\9PA\201023_0.htm 17.08.2011
Installing fuel tank Page 7 of 9
Note
The top left cover must be fitted before the tank is installed.
When installing the tank and rear axle, make sure that cables and
lines are not damaged and are in the correct installation position.
When introducing the tank into the body, a second person should
guide the degassing tank and safeguard it against damage using
wire.
1. Raise the tank with a transmission jack. Make sure to secure the tank with a tension strap to prevent it
from falling.
2. With the help of a second worker, put the tank into the installation position. A second person should
carefully guide the degassing tank.
Note
Note direction arrow stamped on the restraining straps and install
these in the direction of travel.
3. Attach lower covers and fit the four restraining straps, which run
at right angles to the direction of travel. Make sure that the
stamped arrow is pointing forwards in the direction of travel.
Tighten fastening screws to the specified tightening torque. →
Tightening torque: 17 ftlb. Secure fuel filler neck and degassing
tank again with a wire -arrow- .
Figure shows secured degassing tank
(shown here with carbon canister
attached)
4. Lower the transmission jack and fit the centre restraining strap.
The arrow must be pointing forwards. Tighten fastening screws to
the specified torque. → Tightening torque: 17 ftlb.
6. Mount the underbody panel of the side member on the left and right. → 519319 Removing and installing
file://C:\POSES\data\rl\2\9PA\201023_0.htm 17.08.2011
Installing fuel tank Page 8 of 9
middle cover
Holder
8. Then, fit the stone guard on the right side. Mount nuts -arrows-
and tighten to the specified torque. → Tightening torque: 7.5
ftlb.
Stone guard
9. Mount the fuel supply -1- to the connection unit and connect the
2 connection points -2 and 3- .
Connection unit
Subsequent work
file://C:\POSES\data\rl\2\9PA\201023_0.htm 17.08.2011
Installing fuel tank Page 9 of 9
Subsequent work
4. Mount rear axle (spring struts and rear axle housing). → 420519
Removing and installing rear axle housing - chapter on
"Installing"
6. Fill fuel tank (refuel). → Filling with fuel Fastening screws for retaining
brackets of seat-belt buckles
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\201023_0.htm 17.08.2011
Removing and installing fuel level sensor Page 2 of 9
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Information
Component information
Note
The two senders have different shapes and may not be switched.
The float installed in the left direction of travel is flat, while the float installed in the right direction of travel
is spherical.
The removal of both senders is explained in parallel in this description. If only one sender has to be
removed, the other side of the tank can remain untouched.
file://C:\POSES\data\rl\2\9PA\201519_0.htm 17.08.2011
Removing and installing fuel level sensor Page 3 of 9
The effect of fuel and various tolerances means that the left fuel level sensor can become jammed under fuel
lines or the sensor's electric cable. The instrument cluster would then display an incorrect fuel level.
To prevent this, the two fuel lines coming from the left pump and the
electric cable should be tied together with a tie-wrap following repairs.
Preliminary work
Note
If the tank must be opened for emptying, disconnect all connections.
Installation Location:
file://C:\POSES\data\rl\2\9PA\201519_0.htm 17.08.2011
Removing and installing fuel level sensor Page 4 of 9
file://C:\POSES\data\rl\2\9PA\201519_0.htm 17.08.2011
Removing and installing fuel level sensor Page 5 of 9
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. →
Draining and filling fuel
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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.
Fuel supply and disconnection points
→ Wear protective gloves that are fuel-resistant. at right connection unit
→ Wear a breathing mask with active charcoal filter; do not breathe
in any fuel vapours.
→ Ensure that there is adequate ventilation and extract all fuel
vapours.
→ 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.
DANGER
Danger of fire from fuel!
file://C:\POSES\data\rl\2\9PA\201519_0.htm 17.08.2011
Removing and installing fuel level sensor Page 6 of 9
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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.
7. Open the relevant cap with the key T10202 and lift up the
connection unit (cap).
Cap
Preliminary work
Connection unit
file://C:\POSES\data\rl\2\9PA\201519_0.htm 17.08.2011
Removing and installing fuel level sensor Page 7 of 9
1. Install a new tank gauge. Press the sender into its mounting. The
retaining spring must engage audibly.
Subsequent work
Subsequent work
file://C:\POSES\data\rl\2\9PA\201519_0.htm 17.08.2011
Removing and installing fuel level sensor Page 8 of 9
2. Connect connection unit. Connect the electric connectors for the tank gauge and fuel pump. Then push
on the fuel lines. The connectors must engage audibly.
3. Fit connection unit into tank opening. When doing so, make sure that the plastic lug is pointing forwards.
1. Close the tank. To do so, fit the sheetmetal ring and tighten using
the key T10202. → Tightening torque: 104 ftlb.
Cap
2. Fit all connections (fuel lines, ventilation tubes and electric
plugs).
4. Tighten the seat-belt buckle fastening plates. Use three new fastening screws for this and tighten. For
tightening torque, see → 692519 Removing and installing rear belt lock .
file://C:\POSES\data\rl\2\9PA\201519_0.htm 17.08.2011
Removing and installing fuel level sensor Page 9 of 9
as of MY 2003
Country C00, C02, C05, C07,
C08, C09, C10, C11, C12,
C13, C14, C15, C16, C18,
C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46,
Fastening screws for retaining Fastening nuts for cap
C98, C99
brackets of seat-belt buckles
file://C:\POSES\data\rl\2\9PA\201519_0.htm 17.08.2011
Removing carbon canister Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Take up the vehicle at the jacking points provided using a platform lift. → Lifting the vehicle [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1] → Lifting the vehicle [9PAAJ1]
3. Screw the tank cap down. Then remove the rubber sleeve
around the tank filler neck, loosen the 2 M6 x 20 fastening
screws and remove the ground cable.
4. Remove right rear wheel. → 440519 Removing and installing
wheel - chapter on "Removing".
DANGER
Danger of poisoning from fuels!
file://C:\POSES\data\rl\2\9PA\202521_0.htm 17.08.2011
Removing carbon canister Page 3 of 8
DANGER
Danger of fire from fuel!
file://C:\POSES\data\rl\2\9PA\202521_0.htm 17.08.2011
Removing carbon canister Page 4 of 8
→ 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 CO2 or dry powder fire extinguishers.
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
Information
Component information
ATTENTION
Risk of damage!
There is a risk of leaks if the overflow line on the fuel filler neck is above the valve.
file://C:\POSES\data\rl\2\9PA\202521_0.htm 17.08.2011
Removing carbon canister Page 5 of 8
Note
The repair procedure may vary depending on engine type and country equipment. This relates in
particular to components in the right wheel housing.
The following exploded drawing shows the attachment of the tank filler neck and carbon canister in the right
wheel housing.
file://C:\POSES\data\rl\2\9PA\202521_0.htm 17.08.2011
Removing carbon canister Page 6 of 8
1- Fastening screw, M6 x 28
2- Fastening screw M6 x 20
3- Fastening screw
4- Fastening screw M6 x 28
5- Fastening nut M6
6- Carbon canister
7- Degassing tank
file://C:\POSES\data\rl\2\9PA\202521_0.htm 17.08.2011
Removing carbon canister Page 7 of 8
ATTENTION
Risk of damage!
Lines can become kinked or can crack.
1. Loosen the 5 fastening screws on the carbon canister and the Fastening screws
two on the degassing tank in the right wheel housing -arrows- .
Note
In USA vehicles, the rubber hose -2- of the leak diagnosis pump
is extremely tight. If the hose is pulled, the connection piece can
break off at the leak diagnosis pump.
Cutting tie-wraps
4. Remove hose connection on the degassing tank.
ATTENTION
Risk of damage!
file://C:\POSES\data\rl\2\9PA\202521_0.htm 17.08.2011
Removing carbon canister Page 8 of 8
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\202521_0.htm 17.08.2011
Installing carbon canister Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
file://C:\POSES\data\rl\2\9PA\202523_0.htm 17.08.2011
Installing carbon canister Page 3 of 8
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
Component information
file://C:\POSES\data\rl\2\9PA\202523_0.htm 17.08.2011
Installing carbon canister Page 4 of 8
Note
The repair procedure may vary depending on engine type and country equipment. This relates in
particular to components in the right wheel housing.
The following exploded drawing shows the attachment of the tank filler neck and carbon canister in the right
wheel housing.
file://C:\POSES\data\rl\2\9PA\202523_0.htm 17.08.2011
Installing carbon canister Page 5 of 8
1- Fastening screw, M6 x 28
2- Fastening screw M6 x 20
3- Fastening screw
4- Fastening screw M6 x 28
5- Fastening nut M6
6- Carbon canister
7- Degassing tank
file://C:\POSES\data\rl\2\9PA\202523_0.htm 17.08.2011
Installing carbon canister Page 6 of 8
2. Join all lines on the carbon canister and degassing tank at the plug connections.
ATTENTION
Risk of damage!
There is a risk of leaks if the overflow line on the fuel filler
neck is above the valve.
Degassing tank
5. Swivel carbon canister down into installation position from
behind. Make sure that the fuel overflow line -1- is below the
solenoid valve -2- . If the line is not routed correctly, this will
cause damage during subsequent operation.
Picture shows the correct position of the line. View from above without rear side panel.
1 - Overflow line
2 - Solenoid valve
file://C:\POSES\data\rl\2\9PA\202523_0.htm 17.08.2011
Installing carbon canister Page 7 of 8
Fastening screws
Subsequent work
Subsequent work
3. Connect ground cable to fuel filler neck. Screw down the 2 fastening screws and mount rubber sleeve
file://C:\POSES\data\rl\2\9PA\202523_0.htm 17.08.2011
Installing carbon canister Page 8 of 8
Mud flap
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\202523_0.htm 17.08.2011
Fuel filter lines checked (in tank) Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Installation Location:
file://C:\POSES\data\rl\2\9PA\204302_0.htm 17.08.2011
Fuel filter lines checked (in tank) Page 3 of 5
file://C:\POSES\data\rl\2\9PA\204302_0.htm 17.08.2011
Fuel filter lines checked (in tank) Page 4 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
file://C:\POSES\data\rl\2\9PA\204302_0.htm 17.08.2011
Fuel filter lines checked (in tank) Page 5 of 5
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\204302_0.htm 17.08.2011
Removing and installing leakage diagnosis pump (LDP) Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
file://C:\POSES\data\rl\2\9PA\204819_0.htm 17.08.2011
Removing and installing leakage diagnosis pump (LDP) Page 3 of 8
→ 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 CO2 or dry powder fire extinguishers.
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
Preliminary work
Preliminary work
1. Remove carbon canister and place it on a clean surface. → 202521 Removing carbon canister
Information
Component information
file://C:\POSES\data\rl\2\9PA\204819_0.htm 17.08.2011
Removing and installing leakage diagnosis pump (LDP) Page 4 of 8
1 - Degassing tank
2 - Filler neck
3 - Pressure control valve
4 - Carbon canister
5 - Leakage diagnosis pump
1. Loosen three fastening screws on plastic support for pressure control valve. -Arrows-
To remove the top fastening screw, carefully press the pressure control valve hose aside using a
screwdriver and screw out the fastening screw. → Pressure control valve
2. Turn the pressure control valve to the side and remove the three fastening screws on the leakage
diagnosis pump. → Pressure control valve and leakage diagnosis pump mount
file://C:\POSES\data\rl\2\9PA\204819_0.htm 17.08.2011
Removing and installing leakage diagnosis pump (LDP) Page 5 of 8
Rubber flange
5. Pull off the air hose. → Pulling off air hose
6. If the rubber flange slips out of the housing and remains on the connection piece of the leakage
diagnosis pump while you are removing the leakage diagnosis pump, check the rubber flange for
damage and insert it back flush into the carbon canister housing if it is OK. → Rubber flange → Inserted
rubber flange
file://C:\POSES\data\rl\2\9PA\204819_0.htm 17.08.2011
Removing and installing leakage diagnosis pump (LDP) Page 6 of 8
1. If the rubber flange slips out of the housing and remains on the
connection piece of the leakage diagnosis pump while you are
removing the leakage diagnosis pump, check the rubber flange
for damage and insert it back flush into the carbon canister
housing if it is OK. → Rubber flange → Inserted rubber flange
Rubber flange
file://C:\POSES\data\rl\2\9PA\204819_0.htm 17.08.2011
Removing and installing leakage diagnosis pump (LDP) Page 7 of 8
file://C:\POSES\data\rl\2\9PA\204819_0.htm 17.08.2011
Removing and installing leakage diagnosis pump (LDP) Page 8 of 8
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\204819_0.htm 17.08.2011
Removing and installing fuel filter Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
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)
Note
If the tank must be opened for emptying, disconnect all connections.
file://C:\POSES\data\rl\2\9PA\206019_0.htm 17.08.2011
Removing and installing fuel filter Page 3 of 8
Installation Location:
file://C:\POSES\data\rl\2\9PA\206019_0.htm 17.08.2011
Removing and installing fuel filter Page 4 of 8
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. →
Draining and filling fuel
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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.
Fuel supply and disconnection points
→ Wear protective gloves that are fuel-resistant. at right connection unit
→ Wear a breathing mask with active charcoal filter; do not breathe
in any fuel vapours.
→ Ensure that there is adequate ventilation and extract all fuel
vapours.
→ 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.
DANGER
Danger of fire from fuel!
file://C:\POSES\data\rl\2\9PA\206019_0.htm 17.08.2011
Removing and installing fuel filter Page 5 of 8
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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.
7. Open the relevant cap with the key T10202 and lift up the
connection unit (cap).
Cap
Information
Component overview
file://C:\POSES\data\rl\2\9PA\206019_0.htm 17.08.2011
Removing and installing fuel filter Page 6 of 8
Connection unit
file://C:\POSES\data\rl\2\9PA\206019_0.htm 17.08.2011
Removing and installing fuel filter Page 7 of 8
Subsequent work
1. Close the tank. To do so, fit the sheetmetal ring and tighten using
the key T10202. → Tightening torque: 104 ftlb.
Cap
2. Fit all connections (fuel lines, ventilation tubes and electric
plugs).
file://C:\POSES\data\rl\2\9PA\206019_0.htm 17.08.2011
Removing and installing fuel filter Page 8 of 8
4. Tighten the seat-belt buckle fastening plates. Use three new fastening screws for this and tighten. For
tightening torque, see → 692519 Removing and installing rear belt lock .
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\206019_0.htm 17.08.2011
Checking quantity of fuel delivered Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
file://C:\POSES\data\rl\2\9PA\206601_0.htm 17.08.2011
Checking quantity of fuel delivered Page 3 of 6
Special tools
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Information
Test conditions
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WARNING
Danger of fire and injury!
Danger of fire due to escaping fuel, e.g. on hot engine
components or due to electrostatic charge.
Danger of fire due to naked flames and sparks, e.g. during
welding or grinding work.
Note
The fuel gallery is pressurised! Place a cloth near the front of the fuel gallery to prevent fuel dripping onto
hot engine parts.
3. Join the test hose to the measuring adapter and connect the other end to the scavenging valve on the
fuel gallery.
Note
For the delivery rate check, a second person should clock the time.
4. Place the open hose end from the pressure regulator in the measuring beaker.
5. Connect jumper lead 26 to two test leads 16 taken from measurement tool set 9684 and use these to
bridge the fuel pump. The exact assignment of the contacts can be obtained from → Fuse
carrier [9PAAJ1]→ Fuse carrier [9PAAE1 9PAAE7 9PAAF1].
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Checking quantity of fuel delivered Page 6 of 6
Note
To avoid incorrect readings, make sure that the hose lines are
already full of fuel at the start of the test.
6. Keep fuel pump switched on until fuel emerges from the end of
the hose. Then empty the measuring beaker.
7. Switch on fuel pump I (left pump) for one minute. Then monitor
the fuel delivered and note the quantity. Now repeat the process
with pump II (right pump).
Test setup
If the test delivery rate produced in the test is too low, repeat it at the right scavenging valve of the fuel gallery.
8. On completion of the test, switch off the ignition and remove test tool.
DANGER
Danger of fire due to faulty scavenging valves!
9. Press the four rubber elements in the cover onto the four ball Cover
socket holders. The mounts must be felt to engage.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\206601_0.htm 17.08.2011
Removing and installing fuel pump Page 2 of 10
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Empty the fuel tank. → Draining and filling fuel
Information
General note
Note
The fuel pumps have different hose connections and must not be confused.
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Removing and installing fuel pump Page 3 of 10
In order that the connections do not fall in the fuel tank, they should be secured using tie-wraps.
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Removing and installing fuel pump Page 4 of 10
Note
If the tank must be opened for emptying, disconnect all connections.
Installation Location:
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.
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Removing and installing fuel pump Page 5 of 10
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. →
Draining and filling fuel
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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.
Fuel supply and disconnection points
→ Wear protective gloves that are fuel-resistant. at right connection unit
→ Wear a breathing mask with active charcoal filter; do not breathe
in any fuel vapours.
→ Ensure that there is adequate ventilation and extract all fuel
vapours.
→ 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.
DANGER
Danger of fire from fuel!
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Removing and installing fuel pump Page 6 of 10
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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.
7. Open the relevant cap with the key T10202 and lift up the
connection unit (cap).
Cap
Removing left fuel pump
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Removing and installing fuel pump Page 7 of 10
1. Disconnect the electric connectors for the fuel pump and fuel
level sensor. Then pull off the fuel lines on the pressure regulator
and remove the connection unit.
3. Disconnect the hose for the right fuel pump at the Y-piece.
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Removing and installing fuel pump Page 8 of 10
2. Connect the fuel line from the pump to the Y-piece (right side of the tank).
6. Place the connection unit into the tank. When doing so, make sure that the plastic lug is pointing
forwards.
1. Place the pump in the holder on the tank floor and turn it approx. 90° to the right until it is seated
securely.
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Removing and installing fuel pump Page 9 of 10
2. Connect the fuel line from the right pump to the Y-piece.
6. Place the connection unit into the tank. When doing so, make
sure that the plastic lug is pointing forwards.
1. Close the tank. To do so, fit the sheetmetal ring and tighten using
the key T10202. → Tightening torque: 104 ftlb.
Cap
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
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Removing and installing fuel pump Page 10 of 10
Subsequent work
Subsequent work
1. Fill fuel tank (refuel). → Draining and filling fuel
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\206619_0.htm 17.08.2011
Draining and filling fuel Page 2 of 9
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
file://C:\POSES\data\rl\2\9PA\4594979_Tkt_0.htm 17.08.2011
Draining and filling fuel Page 3 of 9
Special tool
A - Fuel transfer unit (This tool has been tested and approved by PORSCHE.); see Workshop
Equipment Manual 3.2.2. "WE 1262"
B - Fuel nozzle - special accessory (This can be used to refuel the vehicle. The fuel nozzle
switches off automatically as soon as the fuel tank is full.); see Workshop Equipment
Manual 3.2.2 "WE 1262"
C - Porsche adapter (This adapter fits 8-mm to 10-mm fuel lines (986; 996 and Cayenne.);
see Workshop Equipment Manual 3.2.2 "WE 1262"
D - Connecting piece between Porsche adapter and suction line (This is screwed into suction
line E and connected to the Porsche adapter.); see Workshop Equipment Manual 3.2.2
"WE 1262"
E - Suction line with venting device (Always attach venting device (rubber taper with
transparent hose) to the filler neck. This minimises the amount of escaping fuel vapours.);
see Workshop Equipment Manual 3.2.2. "WE 1262"
ohne - Adapter adapter 9479 (For controlling the fuel pumps); see Workshop Equipment Manual,
Bezeichnung Chapter 2.2.2
Information
Using equipment
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Draining and filling fuel Page 4 of 9
1. Connect the fuel hose -1- to the changeover tank. Connect the
venting device (transparent hose) to the changeover tank. Then
attach the pneumatic stop switch -3- to the tank and tighten the
two knurled nuts.
2. Connect the suction hose (or fuel nozzle) to the connection -1-
and then connect the venting device -2- .
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Note
Fuel can be removed directly through the fuel filler neck on older
vehicles or vehicles from other manufacturers by removing the
connecting piece.
Connecting piece
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
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Draining and filling fuel Page 6 of 9
ATTENTION
Damage to the fuel tank!
→ Please observe the general warning notes and working regulations. → 10 The most important working
regulations and warning notes.
→ The tank can only be drained using the vehicle's own fuel pumps.
→ It is not possible to extract fuel via the fuel filler opening and doing so may cause damage.
Note
All windows should be opened for better ventilation in the passenger compartment.
4. Reduce the fuel pressure in the fuel line. To do so, screw down
the protective cap on the fuel gallery and carefully press the
valve. Collect emerging fuel with a cloth.
Cap
5. Carefully pull off the fuel line -1- . Collect emerging fuel with a
cloth.
Fuel line
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Porsche adapter
8. Screw the connecting piece into the suction hose and tighten it
hand tight.
Connecting piece
9. Connect the connecting piece to the adapter.
ATTENTION
Risk of damage to fuel pumps!
The Porsche adapter can slip from the tank connection.
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Draining and filling fuel Page 8 of 9
→ Only switch fuel pumps on after the extraction pump has been
switched on.
→ Always set extraction pump to suction mode - never refill mode -
when the vehicle pump is running.
Note
Use special tool adapter 9479 from the measurement tool box to
activate the fuel pump.
11. Remove fuel pump relays -1- and -2- . The pump can be activated by bridging the relevant contacts. The
contact assignment is printed on the corresponding relay. No faults are stored in the engine control
module when special tool adapter 9479 is used. Both pumps should be activated. As soon as the tank is
empty, fit the fuel pump relays again and close the electrics box.
12. Carry out any necessary repair work on the tank. Please observe the warning notes in the chapter
entitled → 10 The most important working regulations and warning notes.
13. Fit all connections (fuel lines, ventilation tubes and electric
plugs).
Connections
14. Fit the lid. Then tighten the four fastening nuts → Tightening torque: 10 (7.5 ftlb.) Nm . Refit carpeted
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Draining and filling fuel Page 9 of 9
Cap
15. Tighten the seat-belt buckle fastening plates. Use three new
fastening screws for this and tighten. For tightening torque see
→ 692519 Removing and installing rear belt lock
16. Fold rear seat down again.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\4594979_Tkt_0.htm 17.08.2011
Replacing air-cleaner element Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
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. → 700219
Removing and installing front cover (engine compartment)
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.
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Replacing air-cleaner element Page 3 of 6
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
Air line
2. Push the circlip into the flange -1- and then pull it off together
with the flange -2- .
Connection
3. Clip the green cap on again after disassembly.
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Replacing air-cleaner element Page 4 of 6
Clamps
6. Press the cover of the air cleaner housing in the direction of the
engine, pulling it upwards at the same time.
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.
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Replacing air-cleaner element Page 5 of 6
Clamps
10. Push cover up against the air cleaner housing and release the 2 fastening clips
11. Push the air suspension line onto the right air cleaner cover.
Subsequent work
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Replacing air-cleaner element Page 6 of 6
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. → 700219 Removing
and installing front cover (engine compartment)
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\242455_1.htm 17.08.2011
Removing and installing air cleaner housing Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
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. → 505619 Removing and installing front wheel housing liner.
Component overview
file://C:\POSES\data\rl\2\9PA\242519_2.htm 17.08.2011
Removing and installing air cleaner housing Page 3 of 5
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.
Air guide
2. Unscrew the fastening screw on the air cleaner housing.
Fastening screw
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.
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Removing and installing air cleaner housing Page 4 of 5
Fastening screw
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.
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Removing and installing air cleaner housing Page 5 of 5
Subsequent work
Subsequent work
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. → 505619 Removing and installing front wheel housing liner.
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\242519_2.htm 17.08.2011
Removing and installing fuel pipe Page 2 of 2
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\243019_0.htm 17.08.2011
Removing and installing cowl for throttle housing (Y-shaped pipe) Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Removing cowl for throttle housing (Y-shaped pipe) - Cayenne S (type M48/00)
1. Remove front engine compartment cover. → 700219 Removing and installing front cover (engine
compartment) - "Removing" section
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Removing and installing cowl for throttle housing (Y-shaped pipe) Page 3 of 5
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.
Fastening bolts
5. Remove the fastening bolts. To do this, take hold of the bolt by
the rubber ring with pliers and pull it out.
Bellows
8. Remove the hose on the Y pipe. To do this, press the button and disconnect the vacuum line.
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Removing and installing cowl for throttle housing (Y-shaped pipe) Page 4 of 5
Vacuum line
1. Attach the vacuum line to the underside of the Y-shaped pipe.
Vacuum line
2. Slide the bellows onto the air flow sensors and tighten the hose
clamps.
Bellows
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
Fastening bolts
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. → 700219 Removing and installing front cover (engine
compartment) - "Installing" section
file://C:\POSES\data\rl\2\9PA\243519_1.htm 17.08.2011
Removing and installing cowl for throttle housing (Y-shaped pipe) Page 5 of 5
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\243519_1.htm 17.08.2011
Removing and installing fuel injector Page 2 of 7
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
2. Remove design covers from engine. → 108319 Removing and installing engine cover - "Removing"
section
Component overview
file://C:\POSES\data\rl\2\9PA\244019_0.htm 17.08.2011
Removing and installing fuel injector Page 3 of 7
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
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Removing and installing fuel injector Page 4 of 7
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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.
Fuel connections
→ Wear protective gloves that are fuel-resistant.
→ Wear a breathing mask with active charcoal filter; do not breathe
in any fuel vapours.
→ Ensure that there is adequate ventilation and extract all fuel
vapours.
→ 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.
DANGER
Danger of fire from fuel!
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
file://C:\POSES\data\rl\2\9PA\244019_0.htm 17.08.2011
Removing and installing fuel injector Page 5 of 7
1. Disconnect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel.
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.
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- .
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Removing and installing fuel injector Page 6 of 7
5. Insert fuel injectors into the openings in the intake module and
press the fuel gallery down.
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Removing and installing fuel injector Page 7 of 7
Subsequent work
Fuel connections
Work subsequent to installing injection valves
1. Install design covers for engine. → 108319 Removing and installing engine cover - "Installing" section
2. Install engine compartment cover at the rear and on the right-hand side. → 700219 Removing and
installing front cover (engine compartment) - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\244019_0.htm 17.08.2011
Removing and installing throttle body Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
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" [9PAAF1 9PAAJ1]→ 243519 Removing and
installing air box for throttle housing (Y-pipe) - section on "Removing" [9PAAE1 9PAAE7]
file://C:\POSES\data\rl\2\9PA\244219_0.htm 17.08.2011
Removing and installing throttle body Page 3 of 5
Suction module
1. Pull off cable plug on the throttle housing and pull cable out of the
clip -Arrows- .
3. Check condition of sealing ring. Replace sealing ring if necessary → Sealing ring for throttle housing .
file://C:\POSES\data\rl\2\9PA\244219_0.htm 17.08.2011
Removing and installing throttle body Page 4 of 5
file://C:\POSES\data\rl\2\9PA\244219_0.htm 17.08.2011
Removing and installing throttle body Page 5 of 5
Subsequent work
Subsequent work
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" [9PAAF1 9PAAJ1]→ 243519 Removing and
installing air box for throttle housing (Y-pipe) - section on "Installing" [9PAAE1 9PAAE7]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\244219_0.htm 17.08.2011
Removing and installing air flow sensor Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
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Removing and installing air flow sensor Page 3 of 5
Bellows
4. Pull out retaining clip on the air flow sensor. → Clamp for hot-film mass air flow meter
5. Pull out air flow sensor.
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Removing and installing air flow sensor Page 4 of 5
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.
Bellows
3. Connect electric connector to the air flow sensor.
9PAAE1, 9PAAE7
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Removing and installing air flow sensor Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\244519_0.htm 17.08.2011
Checking the intake-air distributor for leaks Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Required tools
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Checking the intake-air distributor for leaks Page 3 of 5
Leak test
Note
The specified description can be used to check the intake system from the air cleaner outlet to the
injection valves for leaks.
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Checking the intake-air distributor for leaks Page 4 of 5
Cylinders must not be located in the overlapping TDC. This happens only if the crankshaft was turned
manually.
1. Remove engine compartment cover. → 700219 Removing and installing front cover (engine
compartment) - "Removing" section
Fastening bolts
3. Connect the plugs 9264/7 to the two air cleaner connections and
push in the securing clip.
WARNING
Danger of damaging the intake system if pressure is too high!
Intake system can burst.
Danger of injury from flying components.
WARNING
Danger of injury from flying components.
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Checking the intake-air distributor for leaks Page 5 of 5
→ Do not pull out the oil dipstick or open the engine during the test procedure.
4. Set compressed-air reducer to 0.2 bar (approx. 1.2 bar absolute pressure).
5. Push a compressed-air hose onto the connection from the plug 9264/7 and connect the other end to the
pressure reducer.
Note
Any leaks that exist between the air cleaner cover and the intake
distributor seal can be located using this method.
9. Push the connections onto the cover of the air cleaner housing
and mount and lock the fastening pins.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing intake-air distributor Page 2 of 11
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove design cover → 108319 Removing and installing engine cover - "Removing" section.
Information
Component overview
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Removing and installing intake-air distributor Page 3 of 11
I - Curved hose
II - Check valve
III - Hose
A - Vacuum line closed
B - Vacuum line closed
Vacuum line
Suction module
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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ATTENTION
Risk of damaging the fastening bolts!
The fastening bolts will break if they are turned in the wrong
direction.
→ Only turn the fastening bolts in the correct direction of rotation for
opening and closing.
Fastening bolts
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.
Bellows
6. Remove the vacuum line on the Y-shaped pipe. To do this, press the button and disconnect the vacuum
line.
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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.
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DANGER
Danger of fire from fuel!
DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours 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 vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ 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!
10. Disconnect fuel line -1- and line -2- to the carbon canister on the radiator tank splash panel.
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
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Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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DANGER
Danger of poisoning from fuels!
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DANGER
Danger of fire from fuel!
6. Connect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel.
7. Connect vacuum line to the rear of the intake distributor. The plug must engage audibly.
9. Slide the bellows onto the air flow sensors and tighten the hose clamps.
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Bellows
ATTENTION
Risk of damaging the fastening bolts!
The fastening bolts will break if they are turned in the wrong
direction.
→ 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° Direction of rotation for fastening bolts
clockwise.
Subsequent work
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Removing and installing intake-air distributor Page 11 of 11
1. Install design cover → 108319 Removing and installing engine cover - "Installing" section.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\244619_1.htm 17.08.2011
Removing and installing fuel pressure regulator Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
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)
Note
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Removing and installing fuel pressure regulator Page 3 of 8
Installation Location:
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.
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. →
Draining and filling fuel
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Removing and installing fuel pressure regulator Page 4 of 8
DANGER
Danger of poisoning from
fuels!
→ Gasoline is toxic.
→ Inhaling vapours can
cause irritation of the
mucous membranes and
eyes.
→ It can be carcinogenic. It Fuel supply and disconnection points
represents a serious risk at right connection unit
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
vapours.
→ Ensure that there is
adequate ventilation and
extract all fuel vapours.
→ 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.
DANGER
Danger of fire from fuel!
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Removing and installing fuel pressure regulator Page 5 of 8
Note
The ignition must be switched off when working on the fuel system.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
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.
7. Open the relevant cap with the key T10202 and lift up the
connection unit (cap).
Cap
Information
Component overview
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Removing and installing fuel pressure regulator Page 6 of 8
1. Pull off electric connectors -1 and 2- . Then pull off the fuel lines
-3 and 4- and remove the connection unit (pressure regulator).
Note
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Removing and installing fuel pressure regulator Page 7 of 8
The connection unit together with integrated pressure regulator is replaced as a complete unit and not
disassembled.
Seal
2. Connect the connection unit. Fit electric connector -1 and 2- and
hose connections -3 and 4- .
3. Place the connection unit into the tank. When doing so, make
sure that the plastic lug is pointing forwards.
Connection unit
Subsequent work
1. Close the tank. To do so, fit the sheetmetal ring and tighten using
the key T10202. → Tightening torque: 104 ftlb.
Cap
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
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Removing and installing fuel pressure regulator Page 8 of 8
tightening torque, see → 692519 Removing and installing rear belt lock .
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\245819_0.htm 17.08.2011
Removing and installing oxygen sensors in front of catalytic converter Page 2 of 7
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Removing and installing oxygen sensors in front of catalytic converter Page 3 of 7
Preliminary work
Preliminary work for removing oxygen sensors in front of catalytic converter - Cayenne S
(M48/00)
1. Remove front wheel → 440519 Removing and installing wheel.
2. Remove front wheel housing liner → 505619 Removing and installing front wheel housing liner -
"Removing" section.
3. Remove engine compartment cover above the oxygen sensor plugs → 700219 Removing and installing
front cover (engine compartment) - "Removing" section.
ATTENTION
Danger of burns from hot exhaust system!
6. Release oxygen sensor wire from the cable guide and leave it at the oxygen sensor.
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Removing and installing oxygen sensors in front of catalytic converter Page 4 of 7
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled NR.96-3
sensors
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled NR.97
sensors
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled assembly
sensors NR.98
→ Special tools - oxygen - Torque wrench, signal-transmitting with changeover ratchet NR.90
sensors
ATTENTION
The oxygen sensor cable can be damaged if twisted!
Change in emissions.
Check Engine light comes on.
→ Always release oxygen sensor cable so that the wire can turn when unscrewing or screwing in the
sensor.
→ Do not kink cable.
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Removing and installing oxygen sensors in front of catalytic converter Page 5 of 7
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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.
ATTENTION
The oxygen sensor cable can be damaged if twisted!
Change in emissions.
Check Engine light comes on.
→ Always expose oxygen sensor cable so that the wire can turn
when unscrewing or screwing in the sensor.
→ Do not kink cable.
Subsequent work
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Removing and installing oxygen sensors in front of catalytic converter Page 7 of 7
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.
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\246919_0.htm 17.08.2011
Removing and installing DME control module Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
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.
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:
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Exhaust-gas standard
ME 7.1.1 min
Type Version Explanation
Low Emission Vehicle, USA
OBD 2 LEV
As of model year '03.
Rest of world
RoW EU2
As of model year '03.
European On-Board
EOBD EU4 Diagnosis.
As of model year '03.
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.
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.
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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).
ATTENTION
Risk of short circuit!
Note
Unscrew the two fastening screws for the cowl panel cover and lift up the cover in this area. → 664419
Removing and installing cowl panel cover
1. Push the two retaining clips aside -arrows- and remove control
unit to the front.
1. Insert both connectors into the control unit and push in latch in -direction of arrow- .
2. Insert control unit and secure with the two retaining clips -arrow- .
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Note
If a new DME control module is to be installed in a vehicle, the immobiliser 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.
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
8. Select emission standard and press >> . → 247019 Removing and installing DME control module -
"Information" section
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
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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 immobiliser
code menu and press >> .
13. Enter the new immobiliser 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.
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 immobiliser 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.
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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
8. Select emission standard and press >> . → 247019 Removing and installing DME control module -
"Information" section
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 immobiliser
code menu and press >> .
13. Enter the old immobiliser code (IPAS, vehicle - OLD), continue with the >> key, check the code again
and confirm with F7 .
14. Enter the new immobiliser 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.
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
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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)
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing oxygen sensors behind catalytic converter Page 2 of 7
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
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Removing and installing oxygen sensors behind catalytic converter Page 3 of 7
Preliminary work
ATTENTION
Danger of burns from hot exhaust system!
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Removing and installing oxygen sensors behind catalytic converter Page 4 of 7
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled NR.96-3
sensors
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled NR.97
sensors
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled assembly
sensors NR.98
→ Special tools - oxygen - Torque wrench, signal-transmitting with changeover ratchet NR.90
sensors
file://C:\POSES\data\rl\2\9PA\247319_0.htm 17.08.2011
Removing and installing oxygen sensors behind catalytic converter Page 5 of 7
file://C:\POSES\data\rl\2\9PA\247319_0.htm 17.08.2011
Removing and installing oxygen sensors behind catalytic converter Page 6 of 7
ATTENTION
The oxygen sensor cable can be damaged if twisted!
Change in emissions.
Check Engine light comes on.
→ Always expose oxygen sensor cable so that the wire can turn when unscrewing or screwing in the
sensor.
→ Do not kink cable.
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
file://C:\POSES\data\rl\2\9PA\247319_0.htm 17.08.2011
Removing and installing oxygen sensors behind catalytic converter Page 7 of 7
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\247319_0.htm 17.08.2011
Checking exhaust system for leaks Page 2 of 4
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Lift the vehicle. → 40 Lifting the vehicle
Leak test
ATTENTION
Danger of burns from hot exhaust system!
file://C:\POSES\data\rl\2\9PA\260101_0.htm 17.08.2011
Checking exhaust system for leaks Page 3 of 4
Note
After the connecting clamps in the exhaust system have been released, they must always be replaced.
During assembly work on the exhaust system, ensure that the components are aligned and installed
correctly.
The general warning notes must be observed. → 10 The most important working regulations and warning
notes
Note
The exhaust system must be completely sealed between the
engine and the catalytic converters.
5. Remove the plugs and insert the tailpipes into the rear silencer.
Tyre-inflating device on test valve
Subsequent work
Subsequent work
1. Align tailpipes with the bumper and secure them. → 263415 Aligning tailpipes [9PAAD1 9PAAD7
9PAAE1 9PAAE7]→ 263415 Aligning tailpipes [9PAAF1 9PAAJ1]
file://C:\POSES\data\rl\2\9PA\260101_0.htm 17.08.2011
Checking exhaust system for leaks Page 4 of 4
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\260101_0.htm 17.08.2011
Removing and installing exhaust system Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Information
Component information
file://C:\POSES\data\rl\2\9PA\260119_0.htm 17.08.2011
Removing and installing exhaust system Page 3 of 6
file://C:\POSES\data\rl\2\9PA\260119_0.htm 17.08.2011
Removing and installing exhaust system Page 4 of 6
-C- Inclination Maximum inclination: 10 °
-D- Offset of the rear silencer 2 10 mm
retainer
-E- Off-centre position of central 1 4 mm
mount
-F- Off-centre position of front 1 2 mm
mount
Note
The exhaust system in the V6 is designed as a single strand. Repair instructions and notes apply to both
exhaust systems.
WARNING
Danger of burns from hot exhaust system!
WARNING
Danger of injury from heavy exhaust system!
Note
Before the rear silencer is released, the exhaust system must be supported with a transmission jack or
held by another person.
3. Unscrew the fastening screws on the left and right of the rear silencer.
file://C:\POSES\data\rl\2\9PA\260119_0.htm 17.08.2011
Removing and installing exhaust system Page 5 of 6
file://C:\POSES\data\rl\2\9PA\260119_0.htm 17.08.2011
Removing and installing exhaust system Page 6 of 6
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\260119_0.htm 17.08.2011
Removing and installing exhaust manifold Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
Installation Location:
file://C:\POSES\data\rl\2\9PA\261019_1.htm 17.08.2011
Removing and installing exhaust manifold Page 3 of 5
2. Unclip the oxygen sensor cable from all holders. Remove oxygen
sensor when replacing exhaust manifold.
3. Loosen the 12 fastening nuts in the sequence shown below.
Remove the exhaust manifold.
Fastening nuts
Note
Visually inspect exhaust manifold for cracks and distortion.
If the studs in the cylinder head are damaged, they must be replaced. → 157356 Replace mount for
exhaust manifold (stud) - "Replacing" section
1. Clean sealing surfaces. The surfaces must be free from foreign objects.
2. Use a new seal. The seal must be positioned so that the part number is visible from the outside.
file://C:\POSES\data\rl\2\9PA\261019_1.htm 17.08.2011
Removing and installing exhaust manifold Page 4 of 5
3. Push the manifold across the studs and fit it with 12 new fastening nuts. The fastening nuts are tightened
in two stages in accordance with the tightening sequence → Tightening sequence for fastening nuts →
Tightening torque: 19 ftlb. and → Tightening torque: 24 ftlb. .
4. Fit oxygen sensor when replacing exhaust manifold. For details see → 246919 Removing and installing
oxygen sensor ahead of catalytic converter - "Installing" section. Clip oxygen sensor cable into the
holders.
5. Fit starting catalytic converters with new gaskets. For details see
→ 267619 Removing and installing primary catalytic converter -
"Installing" section.
Subsequent work
1. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
9PAAE1, 9PAAE7
as of MY 2003
file://C:\POSES\data\rl\2\9PA\261019_1.htm 17.08.2011
Removing and installing exhaust manifold Page 5 of 5
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\261019_1.htm 17.08.2011
Checking exhaust system mount Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
ATTENTION
Danger of burns from hot exhaust system!
Note
Check the rubber-metal mounts between the body and the exhaust system for cracks and elongation and
check overall condition.
During the life of the vehicle, the rubber-metal mounts must not soften to such an extent that the exhaust
system starts to hit against adjacent components or the body.
Check the exhaust system for contact with adjacent parts by shaking it manually.
Examine the metal mount for corrosion and damage and check that it is positioned correctly.
The exhaust system must be moved to the correct installation position or damaged components must be
file://C:\POSES\data\rl\2\9PA\262801_0.htm 17.08.2011
Checking exhaust system mount Page 3 of 5
replaced if necessary.
file://C:\POSES\data\rl\2\9PA\262801_0.htm 17.08.2011
Checking exhaust system mount Page 4 of 5
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
file://C:\POSES\data\rl\2\9PA\262801_0.htm 17.08.2011
Checking exhaust system mount Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\262801_0.htm 17.08.2011
Replacing rear silencer Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Information
Component overview
file://C:\POSES\data\rl\2\9PA\263355_0.htm 17.08.2011
Replacing rear silencer Page 3 of 6
file://C:\POSES\data\rl\2\9PA\263355_0.htm 17.08.2011
Replacing rear silencer Page 4 of 6
C Inclination Maximum inclination: 10 °
D Offset of rear silencer retainer 2 10 mm
E Off-centre position of central 1 4 mm
holder
F Off-centre position of front 1 2 mm
holder
Note
The exhaust system in the V6 is designed as a single strand. Repair instructions and notes apply to both
exhaust systems.
file://C:\POSES\data\rl\2\9PA\263355_0.htm 17.08.2011
Replacing rear silencer Page 5 of 6
Note
Before the rear silencer is released, the exhaust system must be
supported with a transmission jack or held by another person.
6. Undo the four fastening screws to the left and right on the rear
silencer and remove the rear silencer from the vehicle.
Note
The exhaust system in the V6 is designed as a single strand. Repair instructions and notes apply to both
exhaust systems.
2. Push the two new connecting clamps onto the exhaust pipes on the rear silencer . Then install the rear
silencer using a transmission jack. Tighten the four fastening screws to the specified tightening torque. →
Tightening torque: 17 ftlb.
3. Push connecting clamps over the exhaust system and align them
→ 263355 Replacing rear muffler - "Information" section. Tighten
fastening screws. → Tightening torque: 44 ftlb.
file://C:\POSES\data\rl\2\9PA\263355_0.htm 17.08.2011
Replacing rear silencer Page 6 of 6
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\263355_0.htm 17.08.2011
Adjusting tailpipes Page 2 of 4
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Adjusting tailpipes
Installation Location:
Overview of tailpipes
file://C:\POSES\data\rl\2\9PA\263415_1.htm 17.08.2011
Adjusting tailpipes Page 3 of 4
Component overview
1 - Rear muffler
2 - 2 mounts (align during installation)
3 - 2 tailpipe clamps
4 - 2 tailpipes (align during installation)
Aligning tailpipes
3. Tighten bolt on tailpipe clamp. → Tightening torque: 44 ftlb. .
file://C:\POSES\data\rl\2\9PA\263415_1.htm 17.08.2011
Adjusting tailpipes Page 4 of 4
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\263415_1.htm 17.08.2011
Removing and installing tailpipes Page 2 of 4
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Installation Location:
file://C:\POSES\data\rl\2\9PA\263419_0.htm 17.08.2011
Removing and installing tailpipes Page 3 of 4
1 - Rear muffler
2 - 2 mounts (align during installation)
3 - 2 tailpipe clamps
4 - 2 tailpipes (align during installation)
1 - Rear muffler
2 - 2 mounts (align during installation)
3 - 2 tailpipe clamps
4 - 2 tailpipes (align during installation)
file://C:\POSES\data\rl\2\9PA\263419_0.htm 17.08.2011
Removing and installing tailpipes Page 4 of 4
3. Clean extension positions and replace tailpipe clamp if necessary depending on the condition.
4. Put tailpipes in installation position and align → 263415 Aligning tailpipes [9PAAD1 9PAAD7 9PAAE1
9PAAE7]→ 263415 Aligning tailpipes [9PAAF1 9PAAJ1].
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\263419_0.htm 17.08.2011
Removing and installing secondary air pump Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Note
The description only relates to one secondary air pump.
Installation Location:
file://C:\POSES\data\rl\2\9PA\266519_0.htm 17.08.2011
Removing and installing secondary air pump Page 3 of 6
file://C:\POSES\data\rl\2\9PA\266519_0.htm 17.08.2011
Removing and installing secondary air pump Page 4 of 6
Component overview
1. Remove hose from secondary air pump. Then separate the electric connector on the secondary air
pump.
file://C:\POSES\data\rl\2\9PA\266519_0.htm 17.08.2011
Removing and installing secondary air pump Page 5 of 6
Note
On the right secondary air
pump also unclip the cooling
water hose and vacuum hose.
Note
On the right secondary air pump also unclip the cooling water hose and vacuum hose.
1. Install bracket and tighten with the three fastening screws. → Tightening torque: 7.5 ftlb.
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
file://C:\POSES\data\rl\2\9PA\266519_0.htm 17.08.2011
Removing and installing secondary air pump Page 6 of 6
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\266519_0.htm 17.08.2011
Removing and installing (main) catalytic converter Page 2 of 12
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove the engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
ATTENTION
Danger of burns from hot exhaust system
Note
Cover the right wing and guide through a ratchet from above using several extensions in order to loosen
the top nut between the primary and main catalytic converters.
Note
If the working height of the vehicle has to be changed due to further work, the transmission support must
be re-fitted using the old bolts.
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Removing and installing (main) catalytic converter Page 3 of 12
1 - 2 exhaust manifolds
2 - 2 exhaust manifold gaskets (replace during installation)
3 - 24 hexagon nuts M8 (replace during installation; coat threads of studs with Microgleit)
4 - 6 Torx screws M8 x 75
5 - 2 turbocharger gaskets (replace during installation)
6 - 2 oxygen sensors ahead of catalytic converter
7 - 2 gaskets (replace during installation)
8 - 16 hexagon nuts M8
9 - Front catalytic converter
10 - Front catalytic converter
11 - Support
12 - Support
13 - 4 hexagon-head bolts M10 x 25
14 - 2 hexagon-head bolts M8 x 15
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Removing and installing (main) catalytic converter Page 4 of 12
Cayenne S (M48/00)
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Removing and installing (main) catalytic converter Page 5 of 12
Transverse strut
2. Release connecting clamps between catalytic converters and
exhaust system. Then push the clamps backwards onto the
exhaust system. The exhaust clamps must not be reused.
4. Remove cardan shaft between front-wheel drive and transfer box -see figure- . → 390219 Removing and
installing front cardan shaft - chapter on "removing" [9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and
installing front cardan shaft - chapter on "removing" [9PAAE7]
file://C:\POSES\data\rl\2\9PA\267319_1.htm 17.08.2011
Removing and installing (main) catalytic converter Page 6 of 12
5. Support transmission with transmission jack. Let main catalytic converter hang down. Unscrew the three
nuts connecting the primary and main catalytic converters. Remove main catalytic converter. Remove
flange gasket.
6. Re-fit transmission support using old screws so that the transmission jack can be removed from under
the vehicle.
ATTENTION
Danger of burns from hot exhaust system
file://C:\POSES\data\rl\2\9PA\267319_1.htm 17.08.2011
Removing and installing (main) catalytic converter Page 7 of 12
1 - 2 exhaust manifolds
2 - 2 exhaust manifold gaskets (replace during installation)
3 - 24 hexagon nuts M8 (replace during installation; coat threads of studs with Microgleit)
4 - 6 Torx screws M8 x 75
5 - 2 turbocharger gaskets (replace during installation)
6 - 2 oxygen sensors ahead of catalytic converter
7 - 2 gaskets (replace during installation)
8 - 16 hexagon nuts M8
9 - Front catalytic converter
10 - Front catalytic converter
11 - Support
12 - Support
13 - 4 hexagon-head bolts M10 x 25
14 - 2 hexagon-head bolts M8 x 15
15 - 2 oxygen sensors behind catalytic converter
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Removing and installing (main) catalytic converter Page 8 of 12
Cayenne S (M48/00)
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Removing and installing (main) catalytic converter Page 9 of 12
Transverse strut
2. Release connecting clamps between catalytic converters and
exhaust system. Then push the clamps backwards onto the
exhaust system. The exhaust clamps must not be reused.
4. Unscrew the three nuts connecting the primary and main catalytic converters and guide out the main
catalytic converter. Remove flange gasket.
file://C:\POSES\data\rl\2\9PA\267319_1.htm 17.08.2011
Removing and installing (main) catalytic converter Page 10 of 12
Nuts connecting primary and main Fastening screws to body and cross
catalytic converters member
Installing (main) catalytic converter, cylinder bank 1 - 4
1. Transmission support removed and transmission supported with jack.
Note
Gaskets and self-locking nuts and bolts must always be replaced!
4. Replace flange gasket and push over the studs of the main
catalytic converter.
Note
To fit the cardan shaft, the transmission must be supported again
and the transmission support removed. Then fit the transmission
support with new screws. → 390219 Removing and installing front
cardan shaft - chapter on "installing" [9PAAE1 9PAAF1 9PAAJ1]
→ 390219 Removing and installing front cardan shaft - chapter on
"installing" [9PAAE7]
file://C:\POSES\data\rl\2\9PA\267319_1.htm 17.08.2011
Removing and installing (main) catalytic converter Page 11 of 12
8. Tighten screws of the catalytic converters to the body and cross member with tightening torque. →
Tightening torque: 17 ftlb.
Transverse strut
Installing (main) catalytic converter, cylinder bank 5 - 8
5. Tighten nuts connecting primary and main catalytic converters to the specified tightening torque. →
Tightening torque: 17 ftlb.
6. Tighten screws of the catalytic converters to the body and cross member with tightening torque. →
Tightening torque: 17 ftlb.
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Removing and installing (main) catalytic converter Page 12 of 12
Transverse strut
Subsequent work
Subsequent work
1. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\267319_1.htm 17.08.2011
Removing and installing primary catalytic converter Page 2 of 10
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove engine compartment cover above the oxygen sensor connectors. → 700219 Removing and
installing front cover (engine compartment) - chapter on "removing"
3. Remove front wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter
on "removing"
4. Remove air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on
"removing"
5. Remove main catalytic converter. → 267319 Removing and installing (main) catalytic converter - chapter
on "removing"
ATTENTION
Danger of burns from hot exhaust system
file://C:\POSES\data\rl\2\9PA\267619_0.htm 17.08.2011
Removing and installing primary catalytic converter Page 3 of 10
Note
Observe the most important working regulations and warning notes. → 10 The most important working
regulations and warning notes
file://C:\POSES\data\rl\2\9PA\267619_0.htm 17.08.2011
Removing and installing primary catalytic converter Page 4 of 10
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 - Gasket; replace
18 - Catalytic converter
19 - Catalytic converter
20 - Screw
21 - Bracket
22 - Bracket
23 - Bracket
24 - Hexagon-head bolt M8 x 25
file://C:\POSES\data\rl\2\9PA\267619_0.htm 17.08.2011
Removing and installing primary catalytic converter Page 5 of 10
ATTENTION
Danger of burns from hot exhaust system
Note
Observe the most important working regulations and warning notes. → 10 The most important working
regulations and warning notes
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Removing and installing primary catalytic converter Page 6 of 10
file://C:\POSES\data\rl\2\9PA\267619_0.htm 17.08.2011
Removing and installing primary catalytic converter Page 7 of 10
3. Remove the three fastening nuts between the exhaust manifold and primary catalytic converter.
Note
Observe the most important working regulations and warning notes. → 10 The most important working
regulations and warning notes
Metal seals and self-locking nuts and bolts must always be replaced!
2. Replace flange gasket and push over the studs of the primary catalytic converter.
4. Through the wheel housing, position fastening screw on catalytic converter bracket.
ATTENTION
Danger of fire and material damage!
→ Lay the oxygen sensor cable so that it cannot touch the exhaust
manifold. Positioning fastening nuts for securing
exhaust manifold to primary catalytic
converter
file://C:\POSES\data\rl\2\9PA\267619_0.htm 17.08.2011
Removing and installing primary catalytic converter Page 8 of 10
8. At the water splash panel, connect the connector for the oxygen
sensor behind catalytic converter.
Note
Observe the most important working regulations and warning notes. → 10 The most important working
regulations and warning notes
Metal seals and self-locking nuts and bolts must always be replaced!
2. Replace flange gasket and push over the studs of the primary catalytic converter.
7. Tighten fastening screw to catalytic converter bracket and nuts to specified tightening torque. →
Tightening torque: 17 ftlb. → Tightening torque: 17 ftlb.
ATTENTION
Danger of fire and material damage!
file://C:\POSES\data\rl\2\9PA\267619_0.htm 17.08.2011
Removing and installing primary catalytic converter Page 9 of 10
9. At the water splash panel, connect the connector for the oxygen
sensor behind catalytic converter.
Subsequent work
Subsequent work
1. Install main catalytic converter. → 267319 Removing and installing (main) catalytic converter - chapter on
"installing"
2. Install air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on "installing"
3. Install front wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
5. Fit engine compartment cover above the oxygen sensor connectors. → 700219 Removing and installing
front cover (engine compartment) - chapter on "installing"
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
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Removing and installing primary catalytic converter Page 10 of 10
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing battery Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Removing battery
Removing battery
Installation Location:
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DANGER
Risk of explosion, injury, short circuit and damage to the generator and electronic control units.
Do not disconnect battery with engine running.
Disconnect and reconnect battery with extreme caution. Risk of short circuit and explosion.
Do not tilt battery when removing it. Risk of acid burns as a result of emerging acid.
Do not rub the battery with a dry cloth. Risk of explosion as a result of static charge.
Note
The battery is located in the battery case under the left front seat.
The vehicle must be supplied with external power at the jump lead starting points so that the seat can be
moved even when the battery is completely discharged. → External power connection, jump lead starting
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Observe the warning notes and safety regulations for lead-acid batteries.→ Warning notes and safety
regulations for lead-acid batteries [9PAAD1 9PAAD7]→ Warning notes and safety regulations for lead-acid
batteries [9PAAE1 9PAAE7 9PAAF1]
Note
For vehicles with a Vehicle Tracking System (VTS), please read the
→ 906323 Vehicle Tracking System (VTS) TI!
3. Fold the carpet sections forward and remove the two fastening
screws -1- .
4. Fold the seat back as far as possible -Arrow B- . With the seat in
its folded position, move the seat forward again using the fore-
and-aft adjustment -Arrow C- .
5. Open the four tension hooks on the battery case cover using a
screwdriver.
6. Remove the battery case cover and air duct.
7. Risk of short circuit! First connect the negative cable -2- , then
the positive -3- .
8. Unscrew the fastening screw on the sheetmetal bracket and remove the sheetmetal bracket.
9. Unscrew the screw on the battery mount and remove the battery mount.
10. Pull off the vent hose on the battery.
Installing battery
Installing battery
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2. Position the battery mount and tighten with the fastening screw.
→ Tightening torque: 17.5 ftlb.
Note
Make sure that the two ends of the vent hose are routed and inserted correctly.
5. Risk of short circuit! First connect the positive cable -3- , then the
negative cable -2- . → Tightening torque: 3.5 ftlb.
7. Attach the four tension hooks on the battery case cover and
close using the screwdriver.
ATTENTION
Risk of material damage to screw connections for seat and seat
frame!
→ 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!
8. Move the seat in its folded position towards the rear -arrow A- and then tip forward -arrow B- .
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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General information on the vehicle battery Page 2 of 12
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Note
To prevent contact corrosion, only approved bolts, nuts, washers, etc. should be used. These elements
have a special surface coating and must be stored separately.
The battery is one of the most important electrical components in the vehicle. Fault-free functioning of the
battery contributes greatly to customer satisfaction. To guarantee long and efficient operation, the battery
must be checked and maintained according to the description in this chapter.
Besides the start function, the battery also has the tasks of buffer and supplier of electrical power for the
entire vehicle electrical system.
Information
Maintenance-free battery:
Note
The tightening torque for the battery terminals is 5 Nm (3.5 ftlb.).
If the battery is to be reconnected, proceed according to → 90 Work instructions after disconnecting the
battery.
Low-maintenance battery:
Note
Battery terminals do not need to be greased.
The battery terminal clamps must only be attached manually without using excessive force to prevent
damage to the battery housing.
If the battery is to be reconnected, proceed according to → 90 Work instructions after disconnecting the
battery.
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To ensure that the battery does not leak, it is essential to ensure that the original plugs supplied with the
battery are screwed into the battery openings.
In the event of loss or damage, only original plugs of the same design should be used.
Note
First aid: Rinse acid splashes in the eyes immediately with clean water for a few minutes. Consult a
doctor immediately. Neutralise acid splashes on the skin or clothing immediately with soap suds and
rinse again with plenty of water. If acid has been drunk unintentionally, consult a doctor immediately.
5. -5- Observe information on the battery in the Technical Manual and in the Driver's Manual.
Note
The battery is located under the left front seat.
In order to avoid triggering the siren in vehicles with an additional alarm siren, the battery must be
disconnected while the ignition is on!
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The battery terminal clamps must only be attached by hand without using excessive force to prevent
damage to the battery housing.
Check that the battery is seated correctly after installation. Otherwise, a loose battery presents risks such
as: - Reduced service life due to vibration damage. - Possible damage to the grid plates of the battery. -
Damage to the battery housing from mounting parts (possible acid leakage, with high subsequent costs).
- Inadequate crash safety.
Note
State of the art batteries are fitted with central venting -A- .
Central venting
In batteries with hose/pipe -A- for the central venting, ensure that
the hose is not pinched. Only then can the battery be freely
vented.
Central venting
Visual inspection
Before measurements such as open-circuit voltage, acid density or the battery load test are carried out, a
visual inspection of the battery must be performed.
Whether the housing of the battery is damaged. Acid can leak out due to damage of the housing.
Whether the battery terminals (battery line connections) are damaged. Contact of the line connections
cannot be guaranteed if the battery terminals are damaged. This can cause a line fire and malfunctions in
the electrical system.
Note
Make sure the vent hose -A- is not kinked or damaged. If in doubt, replace it.
Vent hose -A- must be inserted in the battery and in the battery box.
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Central venting
Checking acid level
1. Switch ignition off and remove ignition key.
4. Fold the carpet cut-outs forwards and remove the two fastening
screws -Arrows 1- .
5. Fold the seat back completely -Arrow B- . With the seat in its
folded position, move the seat forward again using the fore-and-
aft adjustment -Arrow C- .
WARNING
Improper handling of batteries.
Risk of injury and damage to the environment
→ The accident prevention regulations must be strictly observed when handling battery acids.
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Note
Use a commercially available battery filling bottle.
The correct acid level of the battery is an important factor for long and efficient operation of the battery.
When the acid level is too low, a capacity loss (performance loss) of the battery occurs, which is caused
by the cell plates drying out. If the cell plates are not surrounded by electrolyte (battery acid), this will
lead to corrosion of the lead plates, the plate bridges and the cell connectors. The result of the corrosion
is that battery functioning cannot be guaranteed. The battery will become unserviceable.
If the acid level is too high, damage can occur by the battery acid (sulphuric acid/water mixture) leaking
out of the battery.
2. Shine a torch into the battery. The acid level of the battery must be at the protruding lug.
– If the acid level is too low, refill with distilled water using the battery filling bottle.
3. Screw in battery plugs again and ensure that they are seated correctly.
Maintenance-free battery
Note
The maintenance-free battery has an inspection glass.
The charge state and acid level of the battery can be checked through the inspection glass -B- .
If a battery is more than 5 years old and the indicator of the inspection glass is colourless, replace the
battery.
If the battery has been charged, air bubbles can form under the
inspection glass. Before carrying out a visual inspection, tap
carefully on the inspection glass with something like the handle of
a screwdriver.
Maintenance-free battery
Three different colour indications are possible:
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Maintenance-free battery
Colour indication Charge state
Green The battery charge is satisfactory.
Battery will start reliably.
Dark grey The battery has no charge or the charge is too low.
Recharge battery.
Transparent/clear Acid level has become critical.
Replace battery.
WARNING
Improper handling of batteries.
Risk of injury and damage to the environment
→ The accident prevention regulations must be strictly observed when handling battery acids.
→ Wear suitable protective clothing and protective glasses.
→ Only use a torch to illuminate the inside of the battery. Never illuminate the inside of the battery with a
naked flame.
→ Do not handle a naked flame or lighted cigarettes near batteries.
→ Observe the disposal regulations for batteries and sulphuric acid when disposing of batteries.
Note
Only for low-maintenance batteries.
Note
Use commercially available battery acid tester.
The acid density test provides information about the state of the battery in conjunction with the battery
load test.
The density of the acid must be checked as follows in all battery cells (low-maintenance battery) :
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General information on the vehicle battery Page 8 of 12
3. Dip the acid siphon or the pipette into the battery cell and take up the battery acid.
4. Read off the density of the acid in kg/dm³ on the scale of the battery acid tester and compare with the
following table.
Battery charge state in tropical climatic zones (hot countries) Density in kg/dm³
discharged 1.08
half charged 1.16
well charged 1.23
The acid density must be at least 1.24 kg/dm³ in normal climatic zones.
The measured values for the acid density of the individual battery cells must not differ by more than 0.03
kg/dm³ from each other.
Example 2: The acid density in cells 4 and 5 is too low. The acid density deviations between the battery cells
is greater than 0.03 kg/dm³.
– If the nominal values are achieved, screw in the original plugs again.
ATTENTION
Risk of material damage to screw connections for seat and seat frame!
→ 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!
5. Move the seat in its folded position towards the rear -Arrow A- and then tip forward -Arrow B- .
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Note
Use a hand-held multimeter to measure the battery voltage.
Note
After charging and waiting for at least 2 hours, during which time the battery should neither be loaded nor
charged:
– If the hand-held multimeter shows 12.5V or more, the battery voltage is OK.
– If the hand-held multimeter shows a battery voltage below 12.5V: Charge battery.
Note
The acid density test provides information about the state of the battery in conjunction with the battery
load test.
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2. Observe the information in the operating instructions of the battery test device.
3. Connect the clamps of the test lines to the battery terminals as described in the operating instructions of
the test device.
– As the load current varies, the current must be set depending on the battery capacity (operating
instructions of test device).
4. Perform the battery load test in accordance with the operating instructions.
– The result of the battery load test is a voltage value that must be compared with the specified minimum
voltage (limit value).
Table:
Battery capacity: 70 Ah 95 Ah 110 Ah
Cold test current 340 A 450 A 520 A
Load current See tester instructions
Minimum voltage (limit value) See tester instructions
The battery voltage sinks during this test due to the severe load on the battery.
If the battery is in order, the voltage value only decreases to the minimum voltage.
If the battery is faulty, the battery voltage will sink very quickly below the specified minimum voltage.
After the test has taken place, the low voltage value remains over a long period of time; the voltage increases
again slowly.
Charging battery
WARNING
Danger of fire and explosion
→ The battery plugs must always be screwed in correctly when charging and during voltage measurement
and load measurement.
→ Rooms in which batteries are being charged should not be entered with a naked flame or when smoking.
Gases form through the charging process in the batteries which are highly flammable.
Note
A battery charging device is required.
If exhaustively discharged batteries are charged quickly, they will not take up a charge current or they will
be identified too early as full due to the so-called "surface charge".
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3. First disconnect the ground strap of the battery, then the positive battery line.
4. Connect positive line of the battery charging device to the positive terminal of the battery.
5. Connect negative line of the battery charging device to the negative terminal of the battery.
6. Set the charge current on the battery charging device according to the battery capacity.
Batteries which are not in operation for a long period of time discharge.
A battery is exhaustively discharged if the open-circuit voltage has sunk below 11.6 V.see open-circuit
voltage measurement
In exhaustively discharged batteries, the battery acid (sulphuric acid and water mixture) consists of virtually
only water, as the sulphuric acid proportion is considerably reduced.
Exhaustively discharged batteries sulphatise, i.e. the entire plate surfaces of the batteries harden.
If exhaustively discharged batteries are immediately recharged after an exhaustive discharge, the
sulphatisation recedes again.
If these batteries are not recharged, the plates continue to harden and charge take-up ability is limited. A
reduction in the battery performance is the result.
Exhaustively discharged batteries must be charged with a low charge current as follows:
– Set maximum charge current at 10% of battery capacity; i.e. with a 95 Ah battery the maximum charge
current is 9.5 A.
8. Charge battery.
Note
When working or carrying out tests on the Cayenne, or when it is in the workshop, a battery charging
device with a rated current of at least 40 A must be connected.
As soon as the vehicle is unlocked, e.g. the vehicle is in the workshop or salesroom, it must be trickle
charged with a battery charging device.
5. First, connect the positive cable from the charging device to the positive terminal for jump lead starting
-+- . → Tightening torque: 3.5 ftlb.
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6. Connect the negative cable from the charging device to the ground point for jump lead starting - - - . →
Tightening torque: 3.5 ftlb.
7. Set the charge current on the battery charging device according to the battery capacity.
A suitable battery charging device must be connected to the vehicle electrical system when
performing the following tasks. All unnecessary loads must be switched off.
If the doors, bonnet and rear lid are open for a long period of time or if these components are actuated
frequently
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing auxiliary battery Page 2 of 7
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
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.
Installation Location:
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DANGER
Risk of explosion, injury, short circuit and damage to the generator and electronic control units.
2. Observe the warning notes and safety regulations for hydrocyanic acid batteries → 2706 Battery
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7.1. Risk of short circuit! First disconnect the negative cable -arrow 1- , then the positive cable -arrow 2- .
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7.3. Unscrew the battery mount nut and remove the retaining bracket for the battery mount -arrow 5- .
7.4. Risk of causticisation! Remove battery from the battery case by the folding handles, if at all possible
without tilting it.
Note
Make sure that the two ends of the vent hose are routed and
inserted correctly.
1.4. Risk of short circuit! First connect the positive cable -arrow 1- ,
then the negative cable -arrow 2- . → Tightening torque: 3.5
ftlb. Position and tighten retaining strip,
insert breather hose, connect poles
2. Positioning battery case cover and screwing it on:
2.1. Put on the battery case cover, position it and clip in the four fastening clips -arrows A- onto the cover.
2.2. Push the retraining straps across the four fastening bolts on the body floor and screw on the four
fastening nuts -arrows B- . → Tightening torque: 4.5 ftlb.
3. Install subwoofer:
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3.2. Push the electrical plug connection together until the plug is felt to engage.
Note
If the vehicle contains a subwoofer or collapsible spare wheel the
relevant component must be re-installed.
4. Fastening subwoofer:
4.2. Position both fastening nuts -2- and tighten them. → Tightening
Mount for subwoofer
torque: 1.5 ftlb.
as of MY 2003
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Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing three-phase generator Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Before the three-phase generator can be removed, the battery must be disconnected and the terminal
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2. Remove right wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter
on "removing"
3. Remove right air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on
"removing"
4. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
5. Drain coolant . → 193817 Draining and filling in coolant (includes bleeding) - chapter on "draining"
6. Remove drive belt. → 137819 Removing and installing drive belt - chapter on "removing"
Note
When the engine is being cleaned with high-pressure cleaning equipment, make sure that the high
pressure blast is not directed directly onto the three-phase generator (risk of bearing damage).
Installation Location:
Note
If the impact bracket is used, the routing of the wires may differ from this description!
1. Unscrew the three fastening screws -8- for the impact bracket and remove the impact bracket.
2. Unscrew fastening screw -3- of ground lead and lay ground lead to one side.
3. Lever out fastening clips -4- for the electrical lead using a screwdriver.
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Note
If the protective cap cannot be removed, use a knife to carefully
cut if off the three-phase generator. Make sure that the plug
connection and the electrical lead are not damaged and that
there is no more than minimal damage to the protective cap.
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Note
Additional assembly operations must be performed if a new three-phase generator has to be fitted. → 272219
Removing and installing new three-phase generator - chapter on "completing"
6. Tighten electrical B+ lead with fastening nut -5- . → Tightening torque: 11 ftlb.
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Note
Check condition of
protective cap; if it is
damaged it must be
repaired using body
sealant.
11. Attach clip -4- of the electrical lead to the three-phase generator.
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Removing and installing three-phase generator Page 7 of 8
Note
The parts pack of a new three-phase generator contains all the parts required (insulator, PIN and socket).
1. Lay the lead of the new three-phase generator as for the old lead
and clip into the three retaining clips -Arrows A- .
2. Trim the lead (with 2-pole plug) included in the engine wiring
harness to the three-phase generator -arrow- such that, together
with the new lead already laid from the three-phase generator, it
can be joined without tension and without too much slack.
5. Crimp new PIN -2- using repair kit for wiring harnesses
NR.155-1 and repair kit for Cayenne wiring harnesses
NR.155-2 .
6. Insert wire with new PIN into the new socket -3- and lock.
8. Tie the plug connection with a tie-wrap -2- to the nearby wiring
harness.
Subsequent work
Subsequent work
1. Install drive belt. → 137819 Removing and installing drive belt - chapter on "installing"
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2. Fill in coolant. → 193817 Draining and filling in coolant (includes bleeding) - chapter on "filling in"
3. Install right air-cleaner box. → 242519 Removing and installing air cleaner housing - chapter on
"installing"
4. Install right wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
5. Connect the battery and carry out the work instructions. → 90 Work instructions after disconnecting the
battery
6. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing the generator Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Before the generator can be removed, the battery must be disconnected and the terminal covered. → 90
Work instructions after disconnecting the battery
2. Remove right front wheel.→ 440519 Removing and installing wheel - section on "Removing"
3. Remove right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section
on "Removing"
4. Remove right air cleaner housing. → 242519 Removing and installing air cleaner housing - section on
"Removing"
5. Remove engine guard. → 108019 Removing and installing engine guard - section on "Removing"
6. Drain coolant. → 193817 Draining and filling in coolant (includes bleeding) - section on "Draining"
7. Remove drive belt. → 137819 Removing and installing drive belt - section on "Removing"
Note
This description applies to engine numbers as of M48/00 816 09867.
Note
When the engine is being cleaned with high-pressure cleaning equipment, make sure that the high
pressure blast is not directed directly onto the three-phase generator (risk of bearing damage).
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Installation Location:
Overview of generator
1. Unscrew the three fastening screws -8- for the impact bracket
and remove the impact bracket.
3. Lever out fastening clips -4- for the electric line using a
screwdriver.
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Unscrewing fastening screw on the Sealing coolant hoses with hose clip
return connection piece
7. Unscrew fastening screw -2- on the heat protection shield for generator lines.
8. Unscrew fastening nut -5- on the B+ line. Unclip the B+ line at the
two retaining clips -6- and remove it.
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Removing and installing the generator Page 5 of 8
13. Remove the generator through the opening – wheel housing liner
with air-cleaner box removed.
5. Secure the heat protection shield with the generator lines to the generator using the fastening screw -2- .
→ Tightening torque: 10 (7.5 ftlb.) Nm
6. Clip wire harness for the generator in at the three retaining clips -Arrows A- .
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8.1. Grease the new seal on the supply connection piece -1- with Vaseline.
8.2. Press supply connection piece -1- as far as it will go into the supply coolant bore on the generator and
secure with the new fastening screw -2- . → Tightening torque: 10 (7.5 ftlb.) Nm
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Subsequent work
Subsequent work
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Removing and installing the generator Page 8 of 8
1. Install drive belt. → 137819 Removing and installing drive belt - section on "Installing"
2. Fill in coolant. → 193817 Draining and filling in coolant (includes bleeding) - section on "Filling in"
3. Install right air cleaner housing. → 242519 Removing and installing air cleaner housing - section on
"Installing"
4. Install right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section on
"Installing"
5. Fit right front wheel. → 440519 Removing and installing wheel - section on "Installing"
6. Connect the battery and carry out the work instructions. → 90 Work instructions after disconnecting the
battery
7. Fit engine guard. → 108019 Removing and installing engine guard - section on "Installing"
9PAAE1, 9PAAE7
as of MY 2006
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\272219_3.htm 17.08.2011
Replacing the generator Page 2 of 11
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Before the generator can be removed, the battery must be disconnected and the terminal covered. → 90
Work instructions after disconnecting the battery
2. Remove right front wheel.→ 440519 Removing and installing wheel - section on "Removing"
file://C:\POSES\data\rl\2\9PA\272255_1.htm 17.08.2011
Replacing the generator Page 3 of 11
3. Remove right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section
on "Removing"
4. Remove right air cleaner housing. → 242519 Removing and installing air cleaner housing - section on
"Removing"
5. Remove engine guard. → 108019 Removing and installing engine guard - section on "Removing"
6. Drain coolant. → 193817 Draining and filling in coolant (includes bleeding) - section on "Draining"
7. Remove drive belt. → 137819 Removing and installing drive belt - section on "Removing"
Note
This description applies to engine numbers up to M48/00 816 09866.
Note
When the engine is being cleaned with high-pressure cleaning equipment, make sure that the high
pressure blast is not directed directly onto the three-phase generator (risk of bearing damage).
Installation Location:
Overview of generator
1. Unscrew the three fastening screws -8- for the impact bracket and remove the impact bracket.
2. Unscrew fastening screw -3- on ground lead and lay ground lead to one side.
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Replacing the generator Page 4 of 11
3. Lever out fastening clips -4- for the electric line using a screwdriver.
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Replacing the generator Page 5 of 11
10. Remove the generator through the opening – wheel housing liner
with air-cleaner box removed.
Note
The following parts are required for installing the Hitachi generator.
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Replacing the generator Page 6 of 11
1- Generator
2- Return connection piece
3- Supply connection piece
4- 3x screw, M6 x 16
5- 1x hose clamp
6- Heat protection shield
7- 1x screw, M6 x 12
8- 1x line
9- 1x connector
10 - 1x shrink-fit hose
11 - 1x cable connection
Parts -8 to 11- are included in the Repair kit for Cayenne wire harnesses NR.155-2.
1.1. Pull off both caps for the coolant bores -2- on the new generator -1- ( -Arrows A- ).
1.2. Grease the seal -3- on the new return connection piece -4- with Vaseline.
1.3. Press return connection piece -4- as far as it will go into the return coolant bore on the new generator
-1- ( -Arrow B- ) and secure with the new fastening screw -5- . → Tightening torque: 10 (7.5 ftlb.) Nm
2. Insert the generator through the opening - wheel-housing liner with air-cleaner box removed - -Arrow A-
and position it on the engine -Arrow B- .
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Replacing the generator Page 7 of 11
file://C:\POSES\data\rl\2\9PA\272255_1.htm 17.08.2011
Replacing the generator Page 8 of 11
7.1. Grease the seal -2- on the new supply connection piece -1-
with Vaseline.
7.2. Press supply connection piece -1- as far as it will go into the
supply coolant bore on the new generator -Arrow A- and
secure with the new fastening screw -3- . → Tightening torque:
10 (7.5 ftlb.) Nm
7.3. Fit the coolant hose -4- with a new hose clamp -5- and push it
onto the supply connection piece -1- ( -Arrow B- ).
9.1. Push new line -1- with the PIN fully into the connector housing -2- ( -Arrow A- ).
Note
Select a place for the joint where there is enough space to join all the lines present.
Do not cut the lines too short in case they have to be laid in a different position if there is insufficient space in
the area of the joint.
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Replacing the generator Page 9 of 11
Note
The electric lines are located in the splash water area and are thus
exposed to the highest demands.
The greatest care must be taken in the individual work steps for
stripping insulation from, crimping, and shrinking/insulating the electric
lines.
10. Crimp the line from the new generator -1- with the line from the
engine wire harness -4- .
10.1. Trim the line from the engine wire harness -4- so that it can be
joined to the new line that was already laid from the generator
-1- without tension and without too much slack.
10.2. In the engine wire harness -4- , insulate and immobilise the
wire to PIN 2 of the connector that was cut off.
10.3. In the engine wire harness -4- , strip 10 mm of the line to PIN 1
of the connector that was cut off and push new shrink-fit hose
-3- onto the line.
Joining line from new generator to line
10.4. Crimp both lines -1 and 4- using a new crimping sleeve -2- and from engine wire harness
the hand crimping pliers from the Repair kit for wire
harnesses NR.155-1.
10.5. Slide new shrink-fit hose -3- over the crimp connection and carefully shrink it to make it watertight using
the hot-air blower with special nozzle (recommended accessories for the repair kit for wire
harnesses).
11. Wrap commercially available PVC tape all around the area of the connection point.
12. Push the plug connection -1- together until it is felt to engage.
13. Secure wire harness -2- to the wire harness running parallel
using two tie-wraps -3- .
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Replacing the generator Page 10 of 11
14. Grease new sealing ring with Vaseline. Attach return connection piece to the generator and secure with
fastening screws -4- . → Tightening torque: 10 (7.5 ftlb.) Nm
16. Secure ground lead to the generator with the fastening screw -3-
. → Tightening torque: 20 (15 ftlb.) Nm
17. Attach clip -4- on the electric line to the generator.
Subsequent work
Subsequent work
1. Install drive belt. → 137819 Removing and installing drive belt - section on "Installing"
2. Fill in coolant. → 193817 Draining and filling in coolant (includes bleeding) - section on "Filling in"
3. Install right air cleaner housing. → 242519 Removing and installing air cleaner housing - section on
file://C:\POSES\data\rl\2\9PA\272255_1.htm 17.08.2011
Replacing the generator Page 11 of 11
"Installing"
4. Install right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section on
"Installing"
5. Fit right front wheel. → 440519 Removing and installing wheel - section on "Installing"
6. Connect the battery and carry out the work instructions. → 90 Work instructions after disconnecting the
battery
7. Fit engine guard. → 108019 Removing and installing engine guard - section on "Installing"
9PAAE1, 9PAAE7
as of MY 2006
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\272255_1.htm 17.08.2011
Removing and installing starter Page 2 of 5
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Removing"
2. Disconnect battery. → 270619 Removing and reinstalling battery - chapter on "Removing"; → 90 Work
instructions after disconnecting the battery
WARNING
Risk of damage to starter
→ The battery must be properly disconnected before the electric lines are detached on the starter.
Installation Location:
file://C:\POSES\data\rl\2\9PA\276019_1.htm 17.08.2011
Removing and installing starter Page 3 of 5
Overview of starter
1. Unscrew fastening nuts -1- and -2- on the starter, remove the
lines and lay them to one side.
Fastening screws
3. Pull starter forward in the direction of travel -arrow A- , turn slightly -arrow B- and remove in an upward
direction -arrow C- .
1. Place the starter from above on the engine -arrow C- , turn slightly -arrow B- and position in the
mounting -arrow A- on the engine.
file://C:\POSES\data\rl\2\9PA\276019_1.htm 17.08.2011
Removing and installing starter Page 4 of 5
Subsequent work
Subsequent work
1. Install intake distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Installing"
2. Connect the battery . → 270619 Removing and reinstalling battery - chapter on "Installing"; → 90 Work
instructions after disconnecting the battery
file://C:\POSES\data\rl\2\9PA\276019_1.htm 17.08.2011
Removing and installing starter Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\276019_1.htm 17.08.2011
External power connection, jump lead starting Page 2 of 3
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Note
If the battery is flat, jump leads can be used together with the battery of another vehicle to start the car or
to supply external power to the vehicle.
The capacity (Ah) of the battery supplying the power must not be significantly lower than that of the flat
battery.
WARNING
Risk of damage and injury as a result of a short circuit.
→ Use only standard jump leads with a sufficiently wide cross section and fully insulated terminal clamps.
Observe the cable manufacturer's specifications.
→ Route the jump leads so that they cannot become entangled in moving parts in the engine compartment.
→ No contact is allowed between the vehicles, otherwise electricity could flow as soon as the positive
terminal is connected.
The flat battery must be properly connected to the vehicle electrical system.
2. Open protective cover on the positive terminal -+- for jump lead starting -arrow A- .
3. Connect the positive cable to the positive terminal for jump-lead starting -+- , then to the positive terminal
of the battery supplying the power.
4. First, connect the negative cable to the negative terminal of the battery supplying the power, then to the
ground point for jump-lead starting - - - .
5. Have the engine of the vehicle supplying the power run at a higher speed.
6. Start engine. Do not spend longer than 15 seconds trying to start the vehicle with the jump leads - after
15 seconds have elapsed, wait for at least one minute.
file://C:\POSES\data\rl\2\9PA\4611234_Tkt_0.htm 17.08.2011
External power connection, jump lead starting Page 3 of 3
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\4611234_Tkt_0.htm 17.08.2011
Removing and installing ignition switch Page 2 of 6
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove trim panel under dashboard on left. → 701919 Removing and reinstalling trim panel under
dashboard - chapter on "Removing"
Installation Location:
file://C:\POSES\data\rl\2\9PA\280419_1.htm 17.08.2011
Removing and installing ignition switch Page 3 of 6
file://C:\POSES\data\rl\2\9PA\280419_1.htm 17.08.2011
Removing and installing ignition switch Page 4 of 6
Union nut
5. Press connector -arrow- and pull off from ignition starter switch.
file://C:\POSES\data\rl\2\9PA\280419_1.htm 17.08.2011
Removing and installing ignition switch Page 5 of 6
4. Position moulding and press onto the dashboard until the clips engage.
Subsequent work
Subsequent work
1. Install cover under instrument panel on left. → 702219 Removing and reinstalling cover under dashboard
- chapter on "Installing"
Information
Note
In the event of insufficient or non-existent battery positive voltage, the ignition key can be removed using
the emergency operation.
1. Push a ball-point pen, for example, into the opening next to the
key, turn the ignition key to position 0 and pull out.
Ignition key
2. Key in position 0, press release -arrow- and pull key out.
file://C:\POSES\data\rl\2\9PA\280419_1.htm 17.08.2011
Removing and installing ignition switch Page 6 of 6
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\280419_1.htm 17.08.2011
Replacing ignition coils Page 2 of 8
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Switch ignition off and remove ignition key
2. Remove engine compartment cover on the right and rear. → 700219 Removing and reinstalling front
cover (engine compartment) - chapter on "Removing"
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.
Note
Place a cloth between design cover and support for secondary air pump to avoid scratching cover.
file://C:\POSES\data\rl\2\9PA\282055_0.htm 17.08.2011
Replacing ignition coils Page 3 of 8
8. Disconnect the ignition coil. To do this, press the button on the connector and pull off the connector.
9. Loosen ignition coil. To do this, unscrew the fastening screw on the valve cover.
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Replacing ignition coils Page 4 of 8
Ignition coil
11. Reconnect the new ignition coil. Tighten the fastening screws. →
Tightening torque: 7.5 ftlb.
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
(centre of the valve cover) → Initial tightening: 3.5 ftlb. → Final tightening: 7.5 ftlb.
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Replacing ignition coils Page 5 of 8
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.
Install cover
15. Press down the two rubber mountings on the support. The rubber
mountings must be felt to engage.
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.
file://C:\POSES\data\rl\2\9PA\282055_0.htm 17.08.2011
Replacing ignition coils Page 6 of 8
Fastening screw on the torque support Fastening screws for secondary air
bracket pump
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.
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.
7. Reconnect a new ignition coil. Tighten the fastening screws. → Tightening torque: 7.5 ftlb.
file://C:\POSES\data\rl\2\9PA\282055_0.htm 17.08.2011
Replacing ignition coils Page 7 of 8
Pulling the ignition coil out and Fastening screws for ignition coil
replacing it
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.
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Replacing ignition coils Page 8 of 8
11. Tighten the 4 fastening screws on the ignition coils. → Tightening torque: 3.5 ftlb.
Subsequent work
Subsequent work
1. Install engine compartment cover on the right and rear. → 700219 Removing and reinstalling front cover
(engine compartment) - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\282055_0.htm 17.08.2011
Removing and installing hall sender Page 2 of 3
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Removing"
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.
file://C:\POSES\data\rl\2\9PA\283919_0.htm 17.08.2011
Removing and installing hall sender Page 3 of 3
1. Push the hall sender into the camshaft housing and tighten the
fastening screw. → Tightening torque: 7.5 ftlb.
Subsequent work
Subsequent work
1. Install intake distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\283919_0.htm 17.08.2011
Replacing spark plugs Page 2 of 9
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Switch off ignition and remove ignition key.
2. Detach the torque support. To do this, unscrew the fastening screw on the torque support bracket and
pull it out.
file://C:\POSES\data\rl\2\9PA\287055_1.htm 17.08.2011
Replacing spark plugs Page 3 of 9
3. Detach the torque support from the body and swivel upwards.
Note
Place a cloth between design cover and support for secondary air
pump to avoid scratching cover.
file://C:\POSES\data\rl\2\9PA\287055_1.htm 17.08.2011
Replacing spark plugs Page 4 of 9
Removing cover
8. Remove torque arm bracket. To do so, undo the four fastening
screws and set bracket aside.
Note
Place a cloth between secondary air pump and design cover to avoid scratching the cover.
file://C:\POSES\data\rl\2\9PA\287055_1.htm 17.08.2011
Replacing spark plugs Page 5 of 9
file://C:\POSES\data\rl\2\9PA\287055_1.htm 17.08.2011
Replacing spark plugs Page 6 of 9
Ignition coil
ATTENTION
Broken spark plug electrodes can damage the engine!
Bits of electrodes can fall into the combustion chamber.
→ Only check electrode gap of spark plugs, but do not bend them.
→ Spark plugs with an incorrect electrode gap must be replaced.
Note
Use only spark plugs approved by Porsche AG!
file://C:\POSES\data\rl\2\9PA\287055_1.htm 17.08.2011
Replacing spark plugs Page 7 of 9
8.
Tighten spark plugs using special tool spark plug wrench 3122
B. → Tightening torque: 25 (19 ftlb.) Nm , → Tightening
torque: 30 (22 ftlb.) Nm
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.
file://C:\POSES\data\rl\2\9PA\287055_1.htm 17.08.2011
Replacing spark plugs Page 8 of 9
Note
Place a cloth between secondary air pump bracket and design
cover to avoid scratching the cover.
Inserting cover
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.
file://C:\POSES\data\rl\2\9PA\287055_1.htm 17.08.2011
Replacing spark plugs Page 9 of 9
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\287055_1.htm 17.08.2011
Removing and installing knock sensor Page 2 of 4
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Removing"
2. Remove and fold up cover for coolant regulator (thermostat). → 195819 Removing and installing coolant
regulator (thermostat) - chapter on "Removing"
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.
Note
The knock sensor and the cable plug must be aligned so that they never touch!
file://C:\POSES\data\rl\2\9PA\287219_0.htm 17.08.2011
Removing and installing knock sensor Page 3 of 4
ATTENTION
Engine damage and changed exhaust behaviour due to
incorrectly mounted knock sensors!
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- .
Subsequent work
Subsequent work
1. Install cover for coolant regulator (thermostat). → 195819 Removing and installing coolant regulator
(thermostat) - chapter on "Installing"
2. Install intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Installing"
3. Fill and bleed the cooling system. → 193817 Draining and filling coolant (includes bleeding) - chapter on
"Filling"
file://C:\POSES\data\rl\2\9PA\287219_0.htm 17.08.2011
Removing and installing knock sensor Page 4 of 4
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://C:\POSES\data\rl\2\9PA\287219_0.htm 17.08.2011
Removing and installing torque converter sealing ring Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\324719_0.htm 5/19/2011
Removing and installing torque converter sealing ring Page 3 of 5
Preliminary work
2. Remove torque converter. → 325019 Removing and installing torque converter - chapter on
"removing" [9PAAD1]→ 325019 Removing and installing torque converter - chapter on "removing" [9PAAE1
9PAAF1 9PAAJ1]
Installation Location:
1. Using the bolt adapter from the slide hammer kit 168, screw
countersunk head bolt into sealing ring -direction of arrow- .
WARNING
Danger of scalding and chemical burns from hot ATF
file://E:\POSES\data\rl\2\9PA\324719_0.htm 5/19/2011
Removing and installing torque converter sealing ring Page 4 of 5
ring
2. Screw on slide hammer from slide hammer kit 168 and remove sealing ring.
Installation Location:
2. Drive in sealing ring with special tool assembly sleeve 3295 -arrow- until special tool touches transmission
housing.
Subsequent work
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Removing and installing torque converter sealing ring Page 5 of 5
2. Install transmission. → 373519 Removing and installing transmission - chapter on "installing" [9PAAJ1]
→ 373519 Removing and installing transmission - chapter on "installing" [9PAAE1 9PAAF1]→ 373519
Removing and installing transmission - chapter on "installing" [9PAAD1]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\324719_0.htm 5/19/2011
Removing and installing torque converter Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
file://E:\POSES\data\rl\2\9PA\325019_0.htm 5/19/2011
Removing and installing torque converter Page 3 of 5
Installation Location:
Torque converter
WARNING
Danger of scalding and chemical burns from hot ATF
Note
ATF can leak out when removing the torque converter.
Installation Location:
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Removing and installing torque converter Page 4 of 5
Torque converter
Note
Ensure that converter is seated correctly.
Subsequent work
2. Check and if necessary, top up the ATF. → 370235 Checking and topping up the ATF
file://E:\POSES\data\rl\2\9PA\325019_0.htm 5/19/2011
Removing and installing torque converter Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\325019_0.htm 5/19/2011
Checking and topping up the ATF Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Information
ATF cooler line was not opened between thermostat and ATF cooler.
For example: changing transmission, replacing sealing ring on transmission, changing ATF filter, general checks.
Warm up transmission in lower load range. Switch all transmission ranges several times while doing so.
Read out ATF temperature with Porsche System Tester (PST) 2.
ATF temperature: 40 °C.
Selector lever is in position P.
Test and filling process at idle speed.
file://E:\POSES\data\rl\2\9PA\370235_0.htm 5/19/2011
Checking and topping up the ATF Page 3 of 5
ATF cooler line was opened between thermostat and ATF cooler.
For example: replacing ATF, changing ATF line, changing ATF cooler, changing ATF thermostat.
Warm up transmission in lower load range. Switch all transmission ranges several times while doing so.
Read out ATF sump temperature with Porsche System Tester (PST) 2.
The ATF temperature must be 90 °C (coolant circuit open).
Let ATF cool down to 40 °C.
Selector lever is in position P.
Test and filling process at idle speed.
Checking ATF
Checking ATF
Note
Always avoid oil leaks after unscrewing the oil inspection plug. This is caused by a certain amount of oil
which remains on the screw in the lifting tube.
1. Remove engine guard . → 108019 Removing and installing engine guard - section on "Removing"
Note
Secure vehicle to prevent it rolling away.
WARNING
Danger of scalding and chemical burns from hot ATF
Note
Note the test conditions → Test conditions with cooler lines closed→ ATF check screws
Test conditions after opening cooler lines for the following steps.
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Checking and topping up the ATF Page 4 of 5
Note
Undo oil inspection plug -A- only when temperature reaches 40 °C.
5. The oil level is correct when oil emerges at the lifting tube. If this is
not the case, add more ATF. → 370235 Checking and topping up
ATF - section on "Refilling"
Filling in ATF
Topping up ATF
1. Remove engine guard . → 108019 Removing and installing engine guard - section on "Removing"
Note
Secure vehicle to prevent it rolling away.
WARNING
Danger of scalding and chemical burns from hot ATF
file://E:\POSES\data\rl\2\9PA\370235_0.htm 5/19/2011
Checking and topping up the ATF Page 5 of 5
Note
Note the test conditions → Test conditions with cooler lines closed→
Test conditions after opening cooler lines for the following steps.
Note
Undo oil inspection plug only when temperature reaches 40 °C.
Transmission shield
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\370235_0.htm 5/19/2011
Changing ATF Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Changing ATF
Replacing ATF
1. Remove cover of ATF pan. To do this, loosen the two fastening screws -arrows- .
2. Place oil collecting container underneath the vehicle.
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Changing ATF Page 3 of 5
Shield to transmission
WARNING
Danger of scalding and chemical burns from hot ATF
Note
ATF must be changed when the engine/transmission is cold. Check screw and oil drain plug
Note
Only part of the total change quantity can be filled because of the test specifications stipulated for the ATF.
The rest must then be filled as described in the Checking ATF chapter.
4. Screw in oil drain plug -B- with new sealing ring. → Tightening torque: 28 (21 ftlb.) Nm
Note
Counter when loosening the ATF lines.
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Changing ATF Page 4 of 5
WARNING
Danger of scalding and chemical
burns from hot ATF
Note
Counter when fastening the ATF lines.
Note
Modified ATF filling capacity in the transmission in combination with
new control units.
12. Fill with ATF using material 00000 until oil emerges at the lifting
pipe. → Change quantity: 8.5 l or → Change quantity: 9.6 l Check screw and oil drain plug
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Changing ATF Page 5 of 5
Shield to transmission
Subsequent work
2. Check and if necessary, top up the ATF. → 370235 Checking and topping up the ATF
9PAAD1, 9PAAE1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\370255_1.htm 5/19/2011
Removing and installing selector knob Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
Note
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Removing and installing selector knob Page 3 of 4
Installation Location:
ATTENTION
Overstretch the spring in selector knob.
Unlocking button does not return to the initial position.
→ Only move the selector knob as far forward until the tool can be inserted. Avoid any further overstretching.
2. The unlocking hook in the selector knob must retract to the -Hebel grau- . Lock the hook under the button,
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Removing and installing selector knob Page 4 of 4
Note
The button must not be pressed down when the selector knob is
installed.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\370419_0.htm 5/19/2011
Removing and installing selector support Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\370819_0.htm 5/19/2011
Removing and installing selector support Page 3 of 8
Preliminary work
Installation Location:
1. Remove cover of centre console. To do this unscrew two screws -right arrows- , separate plug connection
-inset- , tip cover up -curved arrow- and back and remove.
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Removing and installing selector support Page 4 of 8
2. Remove selector lever cover with special tool unlocking hook 9713. To do this hook into the left and right of
the unlocking bracket -inset- from the front and press outwards. Pull the cover upwards slightly at the same
time.
8. Unscrew cable fastening screw -right arrow- on the cable adjustment using special tool special inserts
model AB NR.170 and remove retaining clip -left arrow- .
9. Remove selector frame.
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Removing and installing selector support Page 5 of 8
Note
When a new selector support is used, the cable adjustment of the selector cable must be modified.
3. When doing so, ensure that the opening for the adjusting screw -arrow- is turned upwards.
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Removing and installing selector support Page 6 of 8
Installation Location:
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Removing and installing selector support Page 7 of 8
8. Install selector lever cover. Make sure that the wiring harness
-arrows- is not pinched in the selector frame.
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Removing and installing selector support Page 8 of 8
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\370819_0.htm 5/19/2011
Selector lever emergency release Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
→ 681919 Removing and installing cover for centre console - "Removing" chapter
Subsequent work
file://E:\POSES\data\rl\2\9PA\3708IN_0.htm 5/19/2011
Selector lever emergency release Page 3 of 3
→ 681919 Removing and installing cover for centre console - "Installing" chapter
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\3708IN_0.htm 5/19/2011
Disassembling and assembling cover for selector lever Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
2. Remove cover of centre console. To do this, unscrew two screws -arrows on right- , separate plug
connection -inset- , tip cover up -curved arrow- and back, and remove.
3. Remove selector lever cover with special tool unlocking hook 9713. To do this hook into the left and right of
the unlocking bracket -inset- from the front and press outwards. Pull the cover upwards slightly at the same
time.
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Disassembling and assembling cover for selector lever Page 3 of 7
Installation Location:
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Disassembling and assembling cover for selector lever Page 4 of 7
Note
Use a clean and soft working surface to disassemble the cover for the selector lever.
Note
Only press the retaining lugs until the shade loosens from the upper part.
1. Release the lugs -arrows- on one side on the underside of the cover
for the selector lever.
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Disassembling and assembling cover for selector lever Page 5 of 7
Note
Use a clean and soft working surface to disassemble the cover for the
selector lever.
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Disassembling and assembling cover for selector lever Page 6 of 7
Subsequent work
2. Install selector lever cover. Make sure that the wiring harness
-arrows- is not pinched in the selector frame.
file://E:\POSES\data\rl\2\9PA\371237_0.htm 5/19/2011
Disassembling and assembling cover for selector lever Page 7 of 7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\371237_0.htm 5/19/2011
Adjusting selector lever cable Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\371515_1.htm 5/19/2011
Adjusting selector lever cable Page 3 of 7
1. Remove selector knob. → 370419 Removing and installing selector knob - chapter on "removing"
2. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
file://E:\POSES\data\rl\2\9PA\371515_1.htm 5/19/2011
Adjusting selector lever cable Page 4 of 7
Cable plug for selector frame cover Releasing selector frame cover
Cable connection for centre console Transverse strut for centre console
7. Pull off electrical plug connections -arrow- .
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Adjusting selector lever cable Page 5 of 7
11. Move shift lever on the transmission to position P, the highest position.
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Adjusting selector lever cable Page 6 of 7
19. Insert centre console cover at the front and tip backwards. Screw in
two screws -right arrows- .
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Adjusting selector lever cable Page 7 of 7
1. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
2. Install selector knob. → 370419 Removing and installing selector knob - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\371515_1.htm 5/19/2011
Removing and installing selector lever cable Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
2. Remove selector frame. → 370819 Removing and installing selector frame - removing
file://E:\POSES\data\rl\2\9PA\371519_1.htm 5/19/2011
Removing and installing selector lever cable Page 3 of 5
Note
When a new selector lever cable is used, this should be connected
directly to the old cable when it is removed. This ensures that it is
routed correctly.
4. Pull selector lever cable up and out through the lower part of the
selector frame.
Note
When a new selector support is used, the cable adjustment of the selector cable must be modified.
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Removing and installing selector lever cable Page 4 of 5
Cable adjustment
Installing selector lever cable
Note
When a new selector lever cable is used, this should be connected to the old cable immediately during
removal. This ensures that it is routed correctly.
Note
The cable adjustment must be changed when a new selector lever cable is used.
1. Install selector lever cable through the lower part of the selector frame.
2. Press rubber sleeve on the selector lever cable into the lower part of the selector frame.
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Removing and installing selector lever cable Page 5 of 5
Note
Ensure that the tab washer is seated correctly.
3. Attach tab washer -A- to the cable holder on the transmission side.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\371519_1.htm 5/19/2011
Removing and installing the Tiptronic control unit Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. The ignition key must be removed before removing the connector from the control unit.
2. Move right front seat all the way back and up.
Installation Location:
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Removing and installing the Tiptronic control unit Page 3 of 8
Installation position
Note
The control unit is located under the right front seat.
1. If the Tiptronic control unit is replaced, observe the points under coding the control unit. → 373019 Removing
and installing Tiptronic control unit - chapter on "Coding"
Note
Only for vehicles with telephone
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Removing and installing the Tiptronic control unit Page 4 of 8
Installation Location:
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Removing and installing the Tiptronic control unit Page 5 of 8
Installation position
1. Insert control unit into the support -A- until the locking tabs -B- are felt
to engage.
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Removing and installing the Tiptronic control unit Page 6 of 8
Note
Only for vehicles with telephone
6. Position the support for the telephone control unit and screw down
using the three fastening nuts.
Note
The adaptation values must be reset using the Porsche System Tester when the transmission is
renewed/replaced.
If a new control unit is installed, it must adapt first. Poor shifting quality can therefore be expected in the
adaptation phase.
After the test drive, let the engine run for 10 minutes at idle speed. This ensures that all adaptation values are
stored in the control unit.
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Removing and installing the Tiptronic control unit Page 7 of 8
The procedure described here has been structured generally; changes or additions may be made. It is based
on Tester Software 16.0.
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.
During coding, 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.
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. >>
Continue.
3. Using the >> key, move from the vehicle type to the list of control units. Perform the automatic control unit
search.
4. Select Tiptronic with the cursor keys and press the >> key.
5. Select Control unit replacement with the cursor keys and press the >> key.
6. Select Read out values (codings) and press the >> key.
7. The message Coding read-out complete will appear on the screen of the Porsche System Tester >> .
8. Switch off ignition and replace Tiptronic control unit. → 373019 Removing and installing Tiptronic control unit -
chapter on "removing"
9. Switch on ignition.
10. After replacement of the control unit, the vehicle data is installed under the menu Write in data read out (see
Section 6). Press the >> key.
11. System Tester displays Coding write-in complete. Press the >> key.
12. Exit the menu, switch off ignition, lock vehicle and read out fault memory once more.
Note
If the data cannot be read out with the Porsche System Tester, the versions listed must be coded using the
menu item "Codings" .
Subsequent work
Subsequent work
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1. For vehicles with a telephone, install the telephone control unit. → 919019 Removing and installing control
unit for telephone - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
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Note
To unscrew the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive harness by
actuating the foot brake.
The colour markings, match points -arrows- , on the cardan shaft and on the all-wheel final drive flange must
be aligned. This will neutralise the residual imbalance of the components.
Note
Screws which are tightened with a torque angle must be replaced with
new ones.
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10. Install cap nut, cap, nut with tab washer and rubber washer on the
multi-functional switch. → Tightening torque: 5 ftlb. → Tightening
torque: 11 ftlb.
Note
When installing the shield, ensure that all fastening parts → Mounting
element shield are present and inserted correctly.
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13. Fix cardan shaft with new screws to the front-axle final drive. → Initial tightening: 22 ftlb. → Final
tightening: 90 Winkel-Grad
Subsequent work
1. Fit engine guard. → 108019 Removing and installing engine guard - installing
9PAAE1, 9PAAF1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Installation Location:
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Note
To unscrew the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive harness by
actuating the foot brake.
The colour markings, match points -arrows- , on the cardan shaft and on the all-wheel final drive flange must
be aligned. This will neutralise the residual imbalance of the components.
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Installation Location:
Note
The colour markings, match points -arrows- , on the cardan shaft and
on the all-wheel final drive flange must be aligned. This will neutralise
the residual imbalance of the components.
Note
Screws which are tightened with a torque angle must be replaced with
new ones.
Note
When installing the shield, ensure that all fastening parts → Mounting
element shield are present and inserted correctly.
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4. Install shield on the transmission. To do this, screw in three fastening screws -arrow- . → Tightening torque:
7.5 ftlb.
5. Fix cardan shaft with new screws to the front-axle final drive. → Initial
tightening: 22 ftlb. → Final tightening: 90 Winkel-Grad
Subsequent work
1. Fit engine guard. → 108019 Removing and installing engine guard - installing
9PAAE1, 9PAAF1
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing sealing ring for selector shaft Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
1. Remove multi-functional switch. → 373119 Removing and installing multi-functional switch - section on
"Removing" [9PAAE1 9PAAF1]→ 373119 21 Removing and installing multi-functional switch - section on
"Removing" [9PAAJ1]
1. Remove engine guard . → 108019 Removing and installing engine guard - section on "Removing"
3. Unscrew selector lever cable from the ball joint with universal disassembly tool NR.21.
4. Push a sharp tool, e.g. scriber, into the sealing ring and remove it. -Arrow-
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1. Press new sealing ring with special tool pressure sleeve T10174 as
far as the pressure sleeve on the transmission housing.
2. Press new sealing ring with special tool pressure sleeve T10174 as far as the pressure sleeve on the
transmission housing. -arrow-
3. Position selector lever on selector shaft and screw in fastening nut. → Tightening torque: 11 ftlb.
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Note
When installing the shield, ensure that all fastening parts -figure- are
present and inserted correctly.
Subsequent work
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1. Install multi-functional switch. → 373119 Removing and installing multi-functional switch - section on
"Installing" [9PAAE1 9PAAF1]→ 373119 23 Removing and installing multi-functional switch - section on
"Installing" [9PAAJ1]
1. Fit engine guard. → 108019 Removing and installing engine guard - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
2. Remove Y-shaped pipe. → 243519 Removing and installing air box for throttle housing (Y-shaped pipe) -
chapter on "Removing" [9PAAF1]→ 243519 Removing and installing air box for throttle housing (Y-shaped
pipe) - chapter on "Removing" [9PAAE1]
3. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
4. Remove exhaust system. → 260119 Removing and installing exhaust system - chapter on "removing"
5. Remove rear cardan shaft. → 393519 Removing and reinstalling rear cardan shaft - chapter on "Removing"
6. Remove front cardan shaft. → 390219 Removing and installing front cardan shaft - chapter on "Removing"
7. Remove catalytic converter on left side. → 267619 Removing and installing primary catalytic converter -
chapter on "Removing" [9PAAE1]→ 267619 Removing and installing primary catalytic converter - chapter on
"Removing" [9PAAF1]→ 267619 Removing and installing primary catalytic converter - Cayenne Turbo -
chapter on "Removing" [9PAAE1]→ 267619 Removing and installing primary catalytic converter - Cayenne
Turbo - chapter on "Removing" [9PAAF1]
Removing transmission
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Removing transmission
Installation Location:
Note
The line connections on the transmission and the ends of the ATF lines must be closed off after the lines
have been separated from the transmission!
3. Remove shield on the left of the transmission. To do this, unscrew three fastening screws -Arrow- .
4. Remove shield on the right of the transmission. To do this, unscrew three fastening screws -Arrow- .
5. Remove transfer box. → 396519 Removing and installing transfer box - chapter on "Removing"
6. Support engine transmission aggregate on converter bell housing with a (material) 00000 on the suspension
subframe.
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Right shield
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Note
A second fitter is required to unscrew or screw in the converter
screws.
13. Remove converter screws. Observe the following steps for this
purpose.
14. Turn crankshaft clockwise with special tool socket wrench insert
97140. Disconnecting converter screws
15. Insert special tool fixing pin 95950 into the front bore on the converter bell housing -Arrow- and hold
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upwards with light pressure until it engages when the crankshaft is turned.
16. Position special tool insert bit 96880 on converter screw through
opening in the engine block, connect bit snap-on head and special
insert 96870 one after the other.
17. Remove special tool fixing pin 95950 before undoing the converter
screws.
WARNING
Danger of scalding and chemical burns from hot ATF
21. Lift transmission with transmission jack and mounting plate on the
ATF pan and secure with belts. ATF line to transmission
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Tool recommendation
Installing transmission
Installing transmission
Installation Location:
Note
A second fitter is required to unscrew or screw in the converter screws.
Note
The adaptation values must be reset using the Porsche System Tester when the transmission is
renewed/replaced. → Removing and installing Tiptronic control unit
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Note
Because of the limited space between the engine and the radiator,
the fixing pin can only be inserted at one point.
Insert special tool in front of the fixing point in the belt pulley and then
turn towards the fixing point. To remove, turn engine back slightly and
remove fixing pin.
Tool recommendation
6. Support transmission with a (material) 00000 between converter bell housing and suspension subframe.
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ATTENTION
Damage to converter screws due to excessive tightening torque.
9. Position bit snap-on head and special tool insert 96870 and tighten
screws. → Tightening torque : 63 ftlb.
13. Pull out special tool fixing pin 95950 before tightening to the
specified tightening torque.
14. Complete the steps described above for the other screws.
WARNING
Danger of scalding and chemical burns from hot ATF
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Right shield
26. Install shield on the left of the transmission. To do this, screw in three
fastening screws -Arrow- . → Tightening torque: 7.5 ftlb.
Left shield
27. Connect oxygen sensor cable to the radiator tank.
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WARNING
Danger of scalding and chemical
burns from hot ATF
Subsequent work
1. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
2. Install front cardan shaft. → 390219 Removing and installing front cardan shaft - chapter on "Installing"
3. Install rear cardan shaft. → 393519 Removing and reinstalling rear cardan shaft - chapter on "Installing"
4. Install the exhaust system. → 260119 Removing and installing exhaust system - chapter on "Installing"
5. Install engine compartment cover on right and rear. → 700219 Removing and reinstalling front cover (engine
compartment) - chapter on "Installing"
6. Check and if necessary, top up the ATF. → 370235 Checking and topping up the ATF
9PAAE1, 9PAAF1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
Note
The adaptation values must be reset using the Porsche System Tester when the transmission is
renewed/replaced. → 373019 Removing and installing Tiptronic control unit - chapter on "removing"
1. Unscrew two screws on the underside of the converter bell housing in the installed transmission.
Removing transmission
Removing transmission
Installation Location:
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Note
Shift lever on the transmission is in position P. Move lever up fully.
Note
A second fitter is required!
1. Unscrew cardan shaft bolts -Arrow- to the transfer box. Counter with
special counterer 3435 on triangular flange -A- .
WARNING
Danger of scalding and chemical burns from hot ATF
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Note
The line connections on the
transmission and the ends of
the ATF lines should be
closed off after the lines have
been separated from the
transmission!
Vent lines
6. Remove reference mark sender on the converter bell housing
-Arrow- .
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10. Insert special tool fixing pin 9595 into the front bore on the converter bell housing -Arrow- and hold
upwards with light pressure until it engages when the crankshaft is turned.
11. Insert special tool Insert bit 9688 through opening in the engine
block on converter screw. Connect special tool insert 9687.
13. Complete the steps described above for the other five screws.
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15. Raise transmission a few centimetres and notch transmission cross member B -A- .
Refitting transmission
Refitting transmission
Installation Location:
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WARNING
Danger of scalding and chemical burns from hot ATF
Note
Since locking is not possible after removal, the cardan shaft can only be tightened to the specified torque
after the engine has been installed.
Screws which are tightened with a torque angle must be replaced with new ones.
1. Fix engine to the crankshaft with special tool fixing pin 9595.
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Note
Screws which are tightened with a torque angle must be replaced
with new ones.
Note
A second fitter is required. Transmission cross member
10. Place screw on special tool insert bit 9688 and screw in screw.
11. Position bit snap-on head and special tool insert 9687 and screw in screw, but do not tighten.
12. Turn crankshaft clockwise with special tool socket wrench insert 9714.
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15. Remove special tool fixing Disconnecting converter screws Opening for converter screw on engine
pin 9595 before tightening
the converter screws to the
specified torque. →
Tightening torque: 63 ftlb.
20. Tighten the fastening screws in cardan shaft -Arrow- to the transfer box.
21. Fasten ATF lines with new sealing rings on the transmission. → Tightening torque: 19 ftlb.
Subsequent work
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Note
The adaptation values must be reset using the Porsche System Tester when the transmission is
renewed/replaced. → 373019 Removing and installing Tiptronic control unit - chapter on "removing"
2. Screw in two screws on the underside of the converter bell housing in the installed transmission.
4. Check and if necessary, top up the ATF. → 370235 Checking and topping up ATF - chapter on "refilling"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Technical data on 6-speed Tiptronic transmission Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Technical values
Technical data
Note
In order to protect the converter components against excessive centrifugal forces when idle, the engine
speed in the selector lever positions P and N is limited to 4,000 rpm.
Transmission ratios
1st gear4.148
2nd gear2.370
3rd gear1.556
4th gear1.155
5th gear0.859
6th gear0.686
Reverse gear3.394
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Note
Modified ATF filling capacities in the transmission in combination with new control units.
Note
Modified ATF filling capacities in the transmission in combination with new control units.
9PAAE1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Installation Location:
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WARNING
Danger of scalding and chemical burns from hot ATF
Shield to transmission
2. Place collection pan under the transmission. Unscrew oil drain plug -B- and drain ATF.
3. Screw in oil drain plug -B- with new sealing ring. → Tightening torque: 21 ftlb.
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Removing and installing ATF pan Page 4 of 6
Note
Make sure that the gasket has been positioned correctly on the bulb of the oil pan edge.
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Removing and installing ATF pan Page 5 of 6
ATF pan
3. Position ATF pan and screw in screws -arrows- . → Tightening torque: 4.5 ftlb.
WARNING
Danger of scalding and chemical burns from hot ATF
4. Unscrew oil inspection plug -A- and fill ATF until constant emission is
visible.
5. Screw in oil inspection plug again -A- with new sealing ring. → Oil inspection plug and oil drain plug
Tightening torque: 52 ftlb.
Subsequent work
Note
Modified ATF filling capacities in the transmission in combination with new control units.
1. Check and if necessary, top up the ATF. → 370235 Checking and topping up the ATF
2. Install shield on ATF pan. To do this, tighten the two fastening screws -arrows- . → Tightening torque: 7.5
ftlb.
3. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
as of MY 2003
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Removing and installing ATF pan Page 6 of 6
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Shield to transmission
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Removing and installing ATF filter Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove ATF pan. → 375519 Removing and installing ATF pan - "Removing" chapter
1. Unscrew three screws -arrows- on the ATF filter and remove filter.
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Removing and installing ATF filter Page 3 of 4
ATTENTION
Leaks between ATF filter and hydraulic control unit
Sealing ring of ATF filter is being pinched.
1. Coat new sealing ring -arrow- with ATF and insert in the hydraulic
control unit.
Subsequent work
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Removing and installing ATF filter Page 4 of 4
1. Install ATF pan. → 375519 Removing and installing ATF pan - installing
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\375819_0.htm 5/19/2011
Removing and installing wire harness in transmission Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
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Removing and installing wire harness in transmission Page 3 of 8
Installation Location:
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Removing and installing wire harness in transmission Page 4 of 8
Note
The adaptation values of the Tiptronic control unit must be reset
using the Porsche System Tester when replacing/renewing the wire
harness. → 373019 Removing and installing Tiptronic control unit
Connector installation
2. Pull off connectors -Arrows- on the solenoid valves -8-12- .
3. Pull off cable plugs -1,5,13- .
Solenoid valves
4. Remove wire harness for solenoid valves through opening in the
housing -Arrow- .
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Removing and installing wire harness in transmission Page 5 of 8
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Removing and installing wire harness in transmission Page 6 of 8
Installation Location:
Note
The adaptation values of the Tiptronic control unit must be reset
using the Porsche System Tester when replacing/renewing the wire
harness. → 373019 Removing and installing Tiptronic control unit
Note
Screws which are tightened with a torque angle must be replaced
with new ones.
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Removing and installing wire harness in transmission Page 7 of 8
3. Plug in cable plug -2- for output shaft speed inductive pickup. -arrow-
4. Install wire set for sensors through opening in the housing.
7. Install wire set for solenoid valves through opening in the housing.
8. Push in the cable plug for the solenoid valves -1,5,8-13- .
Plug installation
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Removing and installing wire harness in transmission Page 8 of 8
Subsequent work
2. Unscrew ATF control screw -A- and fill in ATF until a constant
discharge is visible at the lifting tube.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\381819_0.htm 5/19/2011
Removing and installing oil pressure switch Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
1. Pull off cable plugs from the two oil pressure switches.
2. Remove oil pressure switch.
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Removing and installing oil pressure switch Page 3 of 3
2. Unscrew ATF control screw -A- and fill in ATF until a constant
discharge is visible at the lifting tube.
3. Screw in ATF control screw -A- with new sealing ring. → tightening
torque: 51.8 ftlb.
Note
Observe test conditions after opening cooler lines.
4. Check and top up the ATF. → 370235 Check and top up the ATF -
Chapter "Checking"
ATF inspection plug/drain plug
as of MY 2003
file://E:\POSES\data\rl\2\9PA\384519_0.htm 5/19/2011
Removing and installing ATF cooler Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Installation Location:
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Removing and installing ATF cooler Page 3 of 6
WARNING
Danger of scalding and chemical burns from hot ATF
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Removing and installing ATF cooler Page 4 of 6
WARNING
Danger of scalding and chemical burns from hot ATF
Installation Location:
4. Install the front cross member under the radiators. To do this, tighten the four fastening screws. →
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Removing and installing ATF cooler Page 5 of 6
5. Unscrew ATF control screw -A- and fill in ATF until a constant
discharge is visible at the lifting tube.
Subsequent work
2. Check and if necessary, top up the ATF. → 370235 Checking and topping up the ATF
3. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
file://E:\POSES\data\rl\2\9PA\386019_0.htm 5/19/2011
Removing and installing ATF cooler Page 6 of 6
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\386019_0.htm 5/19/2011
Removing and installing line for ATF cooling Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Installation Location:
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Removing and installing line for ATF cooling Page 3 of 5
WARNING
Danger of scalding and chemical burns from hot ATF
2. Unscrew fastening screw -arrow- which fastens ATF line to the ATF
thermostat and remove line.
3. Unscrew ATF line screw connection to engine oil pan and to ATF line to ATF filter
transmission.
WARNING
Danger of scalding and chemical burns from hot ATF
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Removing and installing line for ATF cooling Page 4 of 5
Installation Location:
2. Screw in ATF line screw connection to engine oil pan → Tightening torque: 7.5 ftlb. and to transmission
bell housing → Tightening torque: 7.5 ftlb. .
5. Unscrew ATF control screw -A- and fill in ATF until a constant discharge is visible at the lifting tube.
6. Screw in ATF control screw with a new sealing ring. → Tightening torque: 52 ftlb.
Subsequent work
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Removing and installing line for ATF cooling Page 5 of 5
4. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\386219_0.htm 5/19/2011
Removing and installing sealing ring for output shaft Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing sealing ring for output shaft Page 3 of 5
Preliminary work
Installation Location:
1. Screw countersunk head bolt and bolt adapter from slide hammer kit NR.168 into sealing ring
-direction of arrow- .
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Removing and installing sealing ring for output shaft Page 4 of 5
2. Screw on slide hammer from slide hammer kit NR.168 and remove sealing ring -Bild- .
Installation Location:
1. Push special tool protective sleeve T10186 -arrow- onto output shaft.
2. Push on sealing ring.
3. Remove special tool protective sleeve T10186 and drive in sealing ring flush using special tool pressure
piece T10180 -arrow- arrow .
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Removing and installing sealing ring for output shaft Page 5 of 5
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\387019_0.htm 5/19/2011
Removing and installing ATF thermostat Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Installation Location:
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Removing and installing ATF thermostat Page 3 of 7
WARNING
Danger of scalding and chemical burns from hot ATF
Note
Counter when loosening the ATF lines. ATF cooler line at thermostat
Note
To prevent oil from spreading into the body front section, a material 00000 should be held underneath.
2. Undo ATF line screw connection on cooler side -Arrow- at the thermostat.
Note
To prevent oil from spreading into the body front section, a material 00000 should be held underneath.
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Removing and installing ATF thermostat Page 4 of 7
Discharge chute
Installation Location:
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Removing and installing ATF thermostat Page 5 of 7
Note
The sealing rings at the ends of the ATF lines on the transmission and cooler sides must be replaced before
installation.
1. Replace sealing rings on the ATF lines and coat with ATF.
2. Connect transmission-side ATF lines to thermostat. Insert the upper line first.
Note
Counter when fastening the ATF lines.
6. Tighten ATF line screw connection on cooler side -Arrow- at the thermostat. → Tightening torque: 22 ftlb.
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Removing and installing ATF thermostat Page 6 of 7
Subsequent work
1. Check and if necessary, top up the ATF. → 370235 Checking and topping up the ATF
2. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
9PAAD1, 9PAAE1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
file://E:\POSES\data\rl\2\9PA\387519_0.htm 5/19/2011
Removing and installing ATF thermostat Page 7 of 7
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\387519_0.htm 5/19/2011
Removing and installing electrohydraulic control unit Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove pipe set in transmission. → 381819 Removing and installing pipe set in transmission - chapter on
"removing"
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Removing and installing electrohydraulic control unit Page 3 of 3
Note
Screws which are tightened with a torque angle must be replaced
with new ones.
Note
The adaptation values of the Tiptronic control unit must be reset
using the Porsche System Tester when replacing/exchanging the
electrohydraulic control unit. → Removing and installing the Tiptronic
control unit Control unit fastening screws
1. Install electrohydraulic control unit. To do this, screw in new fastening screws -Pfeil- . → Initial tightening: 6
ftlb. → Final tightening: 90 degree angle
Subsequent work
1. Install pipe set in transmission. → 381819 Removing and installing pipe set in transmission - chapter on
"installing"
2. Unscrew ATF control screw -A- and fill in ATF until a constant
discharge is visible at the lifting tube.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\387719_0.htm 5/19/2011
Removing and installing rear final drive Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
2. Remove longitudinal interlock servo motor. → 397719 Removing and installing rear-differential lock servo
motor - "Removing" section
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Removing and installing rear final drive Page 3 of 8
Installation Location:
2. Loosen fastening screws for fixing cardan shaft centre bearing holder
to body.
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Removing and installing rear final drive Page 4 of 8
Note
The colour marking, match point, on the cardan shaft and on the
flange of the rear final drive must be installed in alignment -arrows- .
This will neutralise the residual imbalance of the components.
Note
To loosen the cardan shaft on the rear axle transmission, a second
fitter should counter the fastening screws on the triangular flange of
the transfer box. Match points on the cardan shaft
4. Remove cardan shaft from rear axle transmission and tie it up.
Note
To loosen the drive shaft bolts on the rear axle transmission, a
second fitter should sit in the vehicle and block the rear-axle final
drive by actuating the foot brake.
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Removing and installing rear final drive Page 5 of 8
8. Tip drive flange upwards -arrow- and gradually drain rear axle transmission. Remove bleeder line at the
same time.
Note
Screws which are tightened with a torque angle must be replaced
with new ones.
Note
The colour marking, match point, on the cardan shaft and on the flange of the rear final drive must be
installed in alignment -arrows- . This will neutralise the residual imbalance of the components.
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Removing and installing rear final drive Page 6 of 8
Note
To tighten the drive shaft bolts on the rear final drive, a second fitter
should sit in the vehicle and block the rear-wheel drive assembly by
actuating the foot brake.
ATTENTION
Cardan shaft can be damaged by imbalance.
To attach the cardan shaft to the rear final drive, a second fitter should counter the fastening screws on the
triangular flange of the transfer box.
6. Screw in fastening screws for fixing cardan shaft centre bearing holder to body. → Tightening torque: 44
ftlb.
Note
Centre bearing must be installed without tension.
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Removing and installing rear final drive Page 7 of 8
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Removing and installing rear final drive Page 8 of 8
2. Install servo motor for rear-differential lock. → 397719 Removing and installing rear-differential lock servo
motor - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\390119_1.htm 5/19/2011
Removing and installing front cardan shaft Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\390219_0.htm 5/19/2011
Removing and installing front cardan shaft Page 3 of 7
Installation Location:
Note
To unscrew the cardan shaft bolts, a second fitter should sit in the
vehicle and block the drive train by actuating the foot brake.
The colour markings, match points -arrows- on the cardan shaft and
on the all-wheel final drive flange must be aligned. This will neutralise
the residual imbalance of the components.
Note
To unscrew the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive train by
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Removing and installing front cardan shaft Page 4 of 7
The colour markings, match points -arrows- on the cardan shaft and
on the all-wheel final drive flange must be aligned. This will neutralise
the residual imbalance of the components.
2. Detach cardan shaft from final four wheel drive → Front cardan shaft
to all-wheel final drive .
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Removing and installing front cardan shaft Page 5 of 7
Note
If the cardan shaft is to remain
removed, the transmission cross-
member must be refitted.
Installation Location:
Note
The transmission cross member must be disassembled before the cardan shaft is installed.
1. Install cardan shaft between ATF pan and exhaust system support.
2. Fit new exhaust clamps -arrows- . The bolts must point downwards. Note tightening torque. → 260119
Removing and installing exhaust system
file://E:\POSES\data\rl\2\9PA\390219_0.htm 5/19/2011
Removing and installing front cardan shaft Page 6 of 7
Note
Screws which are tightened
with a torque angle must be
replaced with new ones.
Note
Screws which are tightened with a torque angle must be replaced with new ones.
Note
The colour markings, match points -arrows- on the cardan shaft and on the all-wheel final drive flange must
be aligned. This will neutralise the residual imbalance of the components.
Note
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Removing and installing front cardan shaft Page 7 of 7
To tighten the cardan shaft bolts, a second fitter should sit in the
vehicle and block the drive train by actuating the brake.
Note
Screws which are tightened with a torque angle must be replaced
with new ones.
7. Fix cardan shaft with new screws → Front cardan shaft to all-wheel
final drive to the all-wheel final drive. → Initial tightening: 22 ftlb. →
Final tightening: 90 degree angle
Match points of front cardan shaft to
front final drive
8. Fix cardan shaft with new screws -arrow- to the transfer box. →
Initial tightening: 22 ftlb. → Final tightening: 90 degree angle
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\390219_0.htm 5/19/2011
Removing and installing transfer box control module Page 2 of 6
Installation Location:
file://E:\POSES\data\rl\2\9PA\391319_0.htm 5/19/2011
Removing and installing transfer box control module Page 3 of 6
Note
The control unit is located under the right front seat.
1. The ignition key must be removed before removing the connector from the control unit.
2. Move right front seat all the way back and up.
3. For vehicles with a telephone, remove the telephone control unit. → 919019 Removing and installing control
unit for telephone - chapter on "removing"
file://E:\POSES\data\rl\2\9PA\391319_0.htm 5/19/2011
Removing and installing transfer box control module Page 4 of 6
Note
Only for vehicles with
telephone
8. Release the two connectors -A- and pull them off -B- .
Installation Location:
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Removing and installing transfer box control module Page 5 of 6
1. Insert the control unit -A- until the locking tabs -B- are felt to engage.
2. Insert the two connectors -A- and press in the locking mechanism -B- until it is felt to engage.
3. Place the support with the two control units in the installation position -C- .
file://E:\POSES\data\rl\2\9PA\391319_0.htm 5/19/2011
Removing and installing transfer box control module Page 6 of 6
Note
Only for vehicles with telephone
5. Position the support for the telephone control unit and screw down
using the three fastening nuts.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\391319_0.htm 5/19/2011
Removing and installing sealing ring for output flange Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\392219_0.htm 5/19/2011
Removing and installing sealing ring for output flange Page 3 of 6
striker commercially vw
available tool 771/1
Installation Location:
file://E:\POSES\data\rl\2\9PA\392219_0.htm 5/19/2011
Removing and installing sealing ring for output flange Page 4 of 6
1. Remove output flange with special tool striker vw 771/1 and shop-
made tool .
Installation Location:
file://E:\POSES\data\rl\2\9PA\392219_0.htm 5/19/2011
Removing and installing sealing ring for output flange Page 5 of 6
Replacing circlip
2. Drive in new sealing ring with special tool pressure piece t10181
until the special tool touches the transmission housing.
Subsequent work
file://E:\POSES\data\rl\2\9PA\392219_0.htm 5/19/2011
Removing and installing sealing ring for output flange Page 6 of 6
9PAAD7]→ 390119 Removing and installing rear final drive - "Installing" section [9PAAE1 9PAAE7 9PAAF1
9PAAJ1]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\392219_0.htm 5/19/2011
Removing and installing rear cardan shaft Page 2 of 10
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\393519_2.htm 5/19/2011
Removing and installing rear cardan shaft Page 3 of 10
Note
If the cardan shaft or transfer box has to be replaced, please ignore the next step.
Marking the position of the cardan shaft with respect to the transfer box triangular flange serves only to
prevent possible humming noises.
Note
To loosen the cardan shaft on the rear axle transmission, a second
fitter should counter the fastening screws -arrows- at the triangular
flange of the transfer box.
2. The position of the cardan shaft -arrows- with respect to the rear axle transmission flange is marked with a
white dot, match point, on both components.
Note
The colour marking, match point, on the cardan shaft and on the rear final drive flange must be aligned. This
will neutralise the residual imbalance of the components.
file://E:\POSES\data\rl\2\9PA\393519_2.htm 5/19/2011
Removing and installing rear cardan shaft Page 4 of 10
Mark for rear cardan shaft to transfer Match points for cardan shaft to final
box drive
4. Loosen fastening screws -arrow- securing cardan shaft support to
centre bearing.
ATTENTION
Noises caused by damage in the drive line
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Removing and installing rear cardan shaft Page 5 of 10
ATTENTION
Cardan shaft can be damaged if not handled correctly
7. Release cardan shaft centre bearing holder. To do this, unscrew six fastening screws -arrows- .
Note
To prevent the cardan shaft from being damaged, a second mechanic
is required to remove the equipment.
Installation Location:
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Removing and installing rear cardan shaft Page 6 of 10
ATTENTION
Cardan shaft can be damaged if not handled correctly
ATTENTION
Leakage due to damage to centring sleeve
Note
There is no colour marking on the flange to the transfer box for installing new components, transfer box or
cardan shaft. As a result, positioning is not an issue.
If none of the components are replaced, the mark you apply is a precautionary measure in order to avoid
humming noises from the drive line.
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Removing and installing rear cardan shaft Page 7 of 10
Note
To prevent the cardan shaft from being damaged, a second mechanic is required to install the equipment.
2. Pull cardan shaft joints apart so that they sit in the transmission flanges.
3. Screw in six screws -arrow- on the centre bearing holder but do not
tighten.
Note
The colour marking, match point -arrow- , on the cardan shaft and on the flange of the rear final drive must
be aligned. This will neutralise the residual imbalance of the components.
file://E:\POSES\data\rl\2\9PA\393519_2.htm 5/19/2011
Removing and installing rear cardan shaft Page 8 of 10
Note
To attach the cardan shaft to the rear axle transmission, a second
fitter should counter the fastening screws on the triangular flange of
the transfer box.
5. Screw in new screws for cardan shaft flange at the rear axle
transmission. → Initial tightening: 22 ftlb. → Final tightening: 90 °
Match points for cardan shaft to final
drive
6. Tighten bolts connecting cardan shaft triangular flange to transfer
box -arrows- . Counter with an open-ended wrench. → Tightening
torque: 56 ftlb.
Note
Centre bearing must be installed without tension.
file://E:\POSES\data\rl\2\9PA\393519_2.htm 5/19/2011
Removing and installing rear cardan shaft Page 9 of 10
Subsequent work
file://E:\POSES\data\rl\2\9PA\393519_2.htm 5/19/2011
Removing and installing rear cardan shaft Page 10 of 10
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\393519_2.htm 5/19/2011
Removing and installing sealing ring for cardan flange Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\395519_0.htm 5/19/2011
Removing and installing sealing ring for cardan flange Page 3 of 7
striker commercially vw
available tool 771/1
file://E:\POSES\data\rl\2\9PA\395519_0.htm 5/19/2011
Removing and installing sealing ring for cardan flange Page 4 of 7
2. Remove front cardan shaft → 390219 Removing and installing front cardan shaft - chapter on
"Removing" [9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on
"Removing" [9PAAD1 9PAAD7 9PAAE7].
Installation Location:
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Removing and installing sealing ring for cardan flange Page 5 of 7
Marking nut
2. Determine rolling moment of axle transmission with special tool
torque screwdriver for measuring friction moment 89. Push stop
on special tool to zero and turn transmission several times. Note the
displayed value.
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Removing and installing sealing ring for cardan flange Page 6 of 7
Installation Location:
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Removing and installing sealing ring for cardan flange Page 7 of 7
Note
If the rolling moment has to be corrected, this should be done via the
tightening torque of the nut.
Marking nut
Location Explanation Type Basic value Tolerance 1 Tolerance 2
Rolling moment Adjustment value 2.0 (1.5 ftlb.) Nm +0.5 (0.5 ftlb.) Nm
2. Carry out oil check. → 399035 Checking and topping up oil for all-wheel final drive - chapter on "Checking"
3. Install engine guard → 108019 Removing and installing engine guard - chapter on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\395519_0.htm 5/19/2011
Removing and installing sealing ring for output flange Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\395919_0.htm 5/19/2011
Removing and installing sealing ring for output flange Page 3 of 8
striker commercially vw
available tool 771/1
Installation Location:
file://E:\POSES\data\rl\2\9PA\395919_0.htm 5/19/2011
Removing and installing sealing ring for output flange Page 4 of 8
1. Remove flanged shaft with special tool striker vw 771/1 and shop-
made tool .
Installation Location:
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Removing and installing sealing ring for output flange Page 5 of 8
1. Remove flanged shaft with special tool striker vw 771/1 and shop-
made tool .
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Removing and installing sealing ring for output flange Page 6 of 8
Installation Location:
Installation Location:
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Removing and installing sealing ring for output flange Page 7 of 8
Replacing circlip
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Removing and installing sealing ring for output flange Page 8 of 8
"Installing".
2. Check oil for four-wheel final drive. → 399035 Checking and topping up oil for four-wheel final drive - chapter
on "Checking"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\395919_0.htm 5/19/2011
Removing and installing rubber mounting for four-wheel final drive Page 2 of 10
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\396119_0.htm 5/19/2011
Removing and installing rubber mounting for four-wheel final drive Page 3 of 10
Installation Location:
1. Mark rubber mounting for transmission housing at the installation position -arrow- .
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Removing and installing rubber mounting for four-wheel final drive Page 4 of 10
2. Position special tool assembly fixture 9716 a/b on rubber mounting → Removing rubber mounting, drive
side .
Removing rubber mounting for four-wheel final drive, right output side
Installation Location:
1. Mark rubber mounting for transmission housing at the installation position -arrow- .
2. Position special tool assembly fixture 9716 a/b on rubber mounting → Removing right rubber mounting .
Removing rubber mounting for four-wheel final drive, left output side
Installation Location:
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Removing and installing rubber mounting for four-wheel final drive Page 5 of 10
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Removing and installing rubber mounting for four-wheel final drive Page 6 of 10
Installation Location:
Note
Noises in drive line
3. Pull in rubber mounting in direction of travel until installation position is reached. Measure distance between
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Removing and installing rubber mounting for four-wheel final drive Page 7 of 10
Installing rubber mounting for four-wheel final drive, right output side
Installation Location:
Note
Noises in drive line
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Removing and installing rubber mounting for four-wheel final drive Page 8 of 10
Installation position of rubber mounting bulge is incorrect Rubber mounting bulge must be installed vertically
into housing
Installation position of mount in housing is incorrect Pay attention to installation dimension of mount to
housing
1. Mark centre of bulge in rubber mounting → Marking for centre of rubber mounting .
Installation Location:
file://E:\POSES\data\rl\2\9PA\396119_0.htm 5/19/2011
Removing and installing rubber mounting for four-wheel final drive Page 9 of 10
Note
Noises in drive line
Installation position of rubber mounting bulge is incorrect Rubber mounting bulge must be installed vertically
into housing
Installation position of mount in housing is incorrect Pay attention to installation dimension of mount to
housing
2. Position special tool assembly fixture 9716 a/b/c on rubber mounting → Positioning bearing .
file://E:\POSES\data\rl\2\9PA\396119_0.htm 5/19/2011
Removing and installing rubber mounting for four-wheel final drive Page 10 of 10
Positioning bearing
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\396119_0.htm 5/19/2011
Removing and installing rubber mounting for rear final drive Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
file://E:\POSES\data\rl\2\9PA\396119_1.htm 5/19/2011
Removing and installing rubber mounting for rear final drive Page 3 of 8
striker workshop VW
equipment 771/1
Preliminary work
Installation Location:
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Removing and installing rubber mounting for rear final drive Page 4 of 8
Installation Location:
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Removing and installing rubber mounting for rear final drive Page 5 of 8
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Removing and installing rubber mounting for rear final drive Page 6 of 8
Installation Location:
Note
Noises in drive line
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Removing and installing rubber mounting for rear final drive Page 7 of 8
Note
Noises in drive line
Installation Location:
Note
Noises in drive line
Note
Noises in drive line
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Removing and installing rubber mounting for rear final drive Page 8 of 8
Installation position of rubber mounting bulge is incorrect Rubber mounting bulge must be installed vertically
into housing
Installation position of mount in housing is incorrect Pay attention to installation dimension of mount to
housing
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\396119_1.htm 5/19/2011
Removing and installing transfer box Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
file://E:\POSES\data\rl\2\9PA\396519_0.htm 5/19/2011
Removing and installing transfer box Page 3 of 7
Note
To unscrew the cardan shaft bolts, a second fitter should sit in the
vehicle and block the drive train by actuating the foot brake.
1. Remove front cardan shaft on the transfer box and tie it up.
Note
Always observe the exact work sequence when installing/removing the
transmission cross member.
6. Unscrew two transmission cross member screws -B- on transfer box holder.
7. Place a wooden block -arrow- between the converter bell housing and suspension subframe.
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Removing and installing transfer box Page 4 of 7
8. Unscrew fastening nut and push holder with Tiptronic line -A- away to the side.
11. Gradually drain transfer box. Pull out vent line -arrows- and remove it from the retainers on the upper side.
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Removing and installing transfer box Page 5 of 7
Supporting transmission
2. Gradually run in transfer box. Press vent line into holder -arrow- and
attach to transfer box.
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Removing and installing transfer box Page 6 of 7
Transfer box
5. Support transfer box with transmission jack and remove wooden
block between converter bell housing and suspension subframe.
Note
Always observe the exact work sequence when installing/removing the
transmission cross member.
Note
Screws which are tightened with a torque angle must be replaced
with new ones. Supporting transmission
Note
Screws which are tightened with a torque angle must be replaced with new ones.
9. Connect front cardan shaft to transfer box. → Initial tightening: 22 ftlb. → Final tightening: 90 °
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Removing and installing transfer box Page 7 of 7
2. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\396519_0.htm 5/19/2011
Removing and installing transverse lock servo motor Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
file://E:\POSES\data\rl\2\9PA\397719_0.htm 5/19/2011
Removing and installing transverse lock servo motor Page 3 of 5
2. Pull off fastening element -arrow- for cable lead and place lead aside.
ATTENTION
Emerging oil is harmful to the eyes.
Note
Avoid minor oil leaks when removing the servo motor. Servo motor fastening
Installation Location:
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Removing and installing transverse lock servo motor Page 4 of 5
Subsequent work
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing servo motor on transfer box Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
1. Before beginning to work on the servo motor for the transfer box, engage the Low Range offroad driving
program.
2. Disconnect Low Range cable plug -arrow- on the servo motor and loosen cable holder -A- .
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Removing and installing servo motor on transfer box Page 3 of 5
Installation Location:
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Removing and installing servo motor on transfer box Page 4 of 5
Note
If a new servo motor is installed, it is supplied in Low Range position,
offroad driving program.
1. Connect servo motor to the shaft on the transfer box. Position cutout
of the shaft -right inset- to the servo motor -left inset- .
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Removing and installing servo motor on transfer box Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\397819_0.htm 5/19/2011
Removing and installing sealing ring for cardan flange (rear final drive) Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing sealing ring for cardan flange (rear final drive) Page 3 of 7
striker workshop VW
equipment 771/1
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Removing and installing sealing ring for cardan flange (rear final drive) Page 4 of 7
1. Remove rear cardan shaft. → 390119 Removing and installing rear final drive - chapter on
"Removing" [9PAAD1 9PAAD7]→ 390119 Removing and installing rear final drive - chapter on
"Removing" [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
Installation Location:
Note
A second fitter is required for loosening/tightening the flange
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Installation Location:
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Removing and installing sealing ring for cardan flange (rear final drive) Page 6 of 7
Note
A second fitter is required for loosening/tightening the flange
3. Position marking on nut and drive shaft -arrow- again so that the
rolling moment determined prior to removal is reached once again.
Note
If the rolling moment has to be corrected, this should be done via the tightening torque of the nut.
4. Check rolling moment with special tool torque screwdriver for measuring friction moment NR.89. →
Rolling moment: 2.0 ftlb. -0.2 ftlb. +0.2 ftlb.
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2. Check the oil in the final drive. → 399035 Inspecting and adding oil for rear final drive - chapter on
"Checking"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing four-wheel final drive Page 2 of 12
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing four-wheel final drive Page 3 of 12
2. Support engine. → Support engine on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ Support engine on
the body [9PAAD1 9PAAD7] or → Supporting engine on the body [9PAAD1 9PAAD7]→ Supporting engine
on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
3. Remove front wheels. → 440519 Remove and install wheel - Chapter "Removing"
4. Remove engine guard → 108019 Removing and installing engine guard - Chapter "Removing".
5. Remove front cardan shaft → 390219 Install and remove front cardan shaft - Chapter "Removing" [9PAAE1
9PAAF1 9PAAJ1]→ 390219 Install and remove front cardan shaft - Chapter "Removing" [9PAAD1 9PAAD7
9PAAE7].
Installation Location:
1. Clamp steering wheel in centre position with steering wheel holder -figure- .
3. Engage special tool spring compressor VW 552 in top of wheel housing, behind wheel housing liner, and
support the spring strut.
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Note
Supports 1, 2 and 3 must be fitted to the unit lifting platform.
9. Raise unit lifting platform until it bears against the front-axle carrier.
VAG bolts
Note
Fastening screw -left arrow- at front right cannot be removed until
the front-axle carrier is lowered.
VAG bolts
11. Undo bolt connecting spring strut to trailing arm -arrow- .
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ATTENTION
Over-extension of drive shafts on running gear!
15. Lower front-axle carrier with the unit lifting platform. Remove vent line
from the final drive at the same time.
ATTENTION
Risk of damage to ATF lines and pressure line for power steering.
Note
A second fitter is required for removing/installing the four-wheel final Pressing out drive shaft
drive.
18. Tilt forward the transmission housing together with drive flange.
19. Remove four-wheel final drive downwards through the front-axle carrier.
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Installation Location:
ATTENTION
Risk of damage to ATF lines and pressure line for power steering.
Note
A second fitter is required for removing/installing the four-wheel final drive.
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Removing and installing four-wheel final drive Page 8 of 12
3. Insert right drive shaft into output flange and place final drive into the
mounts on the front-axle carrier.
VAG bolts
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Removing and installing four-wheel final drive Page 9 of 12
Note
The front right fastening screw for the four-wheel final drive
-left arrow- can only be screwed in with the front-axle carrier
lowered.
5. Insert fastening screws -arrows- for four-wheel final drive and screw
for drive flange.
Note
Supports 1, 2 and 3 must be fitted to the unit lifting platform. VAG bolts
6. Raise front-axle carrier with unit lifting platform until it bears against the body. Position vent line at the same
time.
Note
For details of tightening torques for running gear parts, see Group 4
(Running gear) → 40 Tightening torques for front axle.
10. Engage servo line in the three holders -arrows- on the front-axle carrier.
11. Screw servo line holders -arrow- on to air-conditioning compressor and clip in the line.
Note
Screws which are tightened with a torque angle must be replaced with new ones.
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Note
For details of tightening torques for running gear parts, see Group 4 (Running gear) → 40 Tightening
torques for front axle.
17. Remove special tool spring compressor VW 552 from spring strut.
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Note
For details of tightening torques for running gear parts, see Group 4 (Running gear) → 40 Tightening
torques for front axle.
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Removing and installing four-wheel final drive Page 12 of 12
2. Remove engine support. → Support engine on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ Support
engine on the body [9PAAD1 9PAAD7] or → Supporting engine on the body [9PAAD1 9PAAD7]
→ Supporting engine on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
3. Install right engine compartment cover → 700219 Remove and install front cover (engine compartment) -
Chapter "Installing".
4. Mount front wheels. → 440519 Remove and install wheel - Chapter "Installing"
5. Calibrate steering angle sensor → 456005 Initialise and calibrate steering angle sensor
7. Install engine guard → 108019 Install and remove engine guard - Chapter "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Checking and topping up oil for transfer box Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
WARNING
Risk of scalding from hot oil
Note
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Checking and topping up oil for transfer box Page 3 of 4
Note
The oil level can only be checked after the vehicle has been idle for 45 minutes.
2. The oil level is correct if the oil reaches the lower edge of the inspection window.
Note
Use only oil approved by Porsche.
3. If this is not the case, top up the oil. → 399035 Inspecting and adding oil for transfer box - chapter on "Filling"
4. Screw in oil inspection plug -A- with new sealing ring. → Tightening torque: 15 ftlb.
WARNING
Risk of scalding from hot oil
Note
The oil level can only be checked after the vehicle has been idle for 45 Inspection/drain plug
minutes.
Note
The vehicle must stand horizontally!
Note
Use only oil approved by Porsche.
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2. Fill with oil using the ATF filling device for filling transmission NR.161 to the lower edge of inspection
plug -A- . Raise filling device.
3. Screw in oil inspection plug -A- with new sealing ring. → Tightening torque: 15 ftlb.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Checking and topping up oil for rear final drive Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
WARNING
Risk of scalding from hot oil
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Checking and topping up oil for rear final drive Page 3 of 4
Note
Vehicle must be horizontal in order to check fluid level in rear final
drive.
2. The oil level is correct if the oil reaches the lower edge of the
inspection window.
3. If this is not the case, top up the oil. → 399035 Inspecting and adding oil for rear final drive - chapter on
"Filling"
WARNING
Risk of scalding from hot oil
Note
Vehicle must be horizontal in order to fill rear final drive. Control/drain plug for rear final drive
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Checking and topping up oil for rear final drive Page 4 of 4
Note
Use only oil approved by Porsche.
2. Fill with oil using the ATF filling device for filling transmission NR.161 to the lower edge of inspection
plug -A- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Checking and topping up oil for four-wheel final drive Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Checking and topping up oil for four-wheel final drive Page 3 of 5
1. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
WARNING
Risk of scalding from hot oil
Note
Vehicle must be horizontal to check oil level in all-wheel final drive. Oil inspection plug-filler screw
1. Unscrew oil inspection plug -A- with tool special inserts mod. AB 170.
2. The oil level is correct if the oil reaches the lower edge of the inspection window.
3. If this is not the case, top up the oil. → 399035 Checking and topping up oil for all-wheel final drive - chapter
on "Filling"
4. Screw in oil inspection plug -A- with new sealing ring. To do this, use the special tool special inserts model
AB 170 and accessory for the torque wrench: open ring wrench insert a/f 13 + adapter 98-1. →
Tightening torque: 26 ftlb.
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WARNING
Risk of scalding from hot oil
Note
Vehicle must be horizontal in order to fill final drive. Oil inspection plug-filler screw
1. Unscrew oil inspection plug -A- with tool special inserts mod. AB 170.
Note
Use only oil approved by Porsche.
2. Fill with oil using the ATF filling device for filling transmission 161 to the lower edge of inspection plug
-A- .
3. Screw in oil inspection plug -A- with new sealing ring. To do this, use
the special tool special inserts model AB 170 and accessory for
the torque wrench: open ring wrench insert a/f 13 + adapter 98-
1. → Tightening torque: 26 ftlb.
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Changing oil for four-wheel final drive Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Changing oil for four-wheel final drive Page 3 of 4
WARNING
Risk of scalding from hot oil
3. Screw in oil drain plug -B- with a new sealing ring. → Tightening
torque: 26 ftlb. Oil inspection and drain plug
4. Unscrew oil inspection plug using the special inserts model AB 170
tool.
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Changing oil for four-wheel final drive Page 4 of 4
Note
Use only oil approved by Porsche.
5. Using the ATF filling device for filling transmission 161, fill with oil
up to the lower edge of the oil inspection plug -A- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Changing oil for rear final drive Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
WARNING
Risk of scalding from hot oil
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Changing oil for rear final drive Page 3 of 3
3. Screw in oil drain plug -B- with new sealing ring. → Tightening torque: 26 ftlb.
WARNING
Risk of scalding from hot oil
Note
Vehicle must be horizontal in order to fill rear final drive.
5. Fill with oil using the ATF filling device for filling transmission 161 to the lower edge of inspection plug
opening -A- . → Tightening torque: 1.25 l +0.35 l
6. Screw in oil inspection plug -A- with new sealing ring. → Tightening
torque: 26 ftlb.
7. Check oil for rear final drive → 399035 Checking and topping up oil
for rear final drive - chapter on "Checking"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Changing oil for transfer box Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
WARNING
Risk of scalding from hot oil
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Changing oil for transfer box Page 3 of 4
3. Screw in oil drain plug -B- with new sealing ring. → Tightening
torque: 15 ftlb.
Note
Vehicle must be horizontal in order to fill the transfer box.
Note
Use only oil approved by Porsche.
5. Fill with oil to the lower edge of the inspection plug opening -A- using
the ATF filling device for filling transmission 161. Raise filling Oil inspection and drain plug
device.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
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Changing oil for transfer box Page 4 of 4
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing sealing ring for rear transfer box (output flange) Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing sealing ring for rear transfer box (output flange) Page 3 of 6
striker commercially vw
available tool 771/1
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Removing and installing sealing ring for rear transfer box (output flange) Page 4 of 6
ATTENTION
Leakage due to scores on the sealing face.
→
When removing the sealing ring, place the tip of the hook on the sealing ring only and not on the sealing
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Removing and installing sealing ring for rear transfer box (output flange) Page 5 of 6
1. Drive in new sealing ring with special tool pressure piece T10185
until the special tool touches the transmission housing.
Note
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Removing and installing sealing ring for rear transfer box (output flange) Page 6 of 6
Caulking nuts
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing sealing ring for front transfer box output Page 2 of 9
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing sealing ring for front transfer box output Page 3 of 9
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Removing and installing sealing ring for front transfer box output Page 4 of 9
striker commercially vw
available tool 771/1
3. Support transmission with material 00000 and secure with retaining band.
4. Unscrew four exhaust system screws on the cross member -centre arrow- and unscrew screw connection
holder on body -right arrow- .
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Removing and installing sealing ring for front transfer box output Page 5 of 9
6. Unscrew two screws on the cross member -B- on the transfer box holder and remove transmission cross
member.
Installation Location:
1. Unscrew collar nut of output flange with special tool socket t10204. To do this, block flange with special tool
arm bracket 3435.
3. Remove output flange with shop made tool and striker vw 771/1.
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Removing and installing sealing ring for front transfer box output Page 6 of 9
Installation Location:
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Removing and installing sealing ring for front transfer box output Page 7 of 9
Note
Ensure that the round seal -arrow- is inserted.
1. Drive in new sealing ring with special tool pressure piece T10185
→ Driving in the sealing ring until the special tool touches the
transmission housing.
Round seal on output flange
2. Install output flange and, if necessary, drive in with a plastic hammer.
Note
Ensure that the round seal -arrow- is inserted.
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Caulking nuts
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing sealing ring for transfer box input shaft Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing sealing ring for transfer box input shaft Page 3 of 4
1. Remove transfer box. → 396519 Removing and installing transfer box - chapter on "Removing"
ATTENTION
Damage to input shaft bearing.
1. Using the bevelled attachment from the slide hammer kit 168, make
a small hole -figure- in the sealing ring.
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Removing and installing sealing ring for transfer box input shaft Page 4 of 4
1. Fill the space between the dust and sealing lips on the new sealing
ring with grease.
Subsequent work
2. Check oil for transfer box. → 399035 Check and top up oil for transfer box - Chapter "Checking"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\399219_2.htm 5/19/2011
Information Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
39 IN Information - as of MY 2003
Porsche Traction Management, or PTM, is a system which guarantees or improves the traction of the vehicle.
Two controllable locks are available in the system.
It operates permanently and receives values from different sensors (e.g. steering-angle sensor, lateral
acceleration sensor) from which the corresponding lock controls are obtained. In this way the optimum power is
distributed to the drive wheels.
Longitudinal lock (in the transfer box): Distributes the moment released by the gear via the cardan shafts to
the front or rear axle gear.
Longitudinal interlock (depending on the equipment in the rear final drive): Distributes the moment to the two
rear driving wheels.
Porsche Traction Management, or PTM, is a system which guarantees or improves the traction of the vehicle.
Two locks available in the system can be activated.
It operates permanently and receives values from different sensors (e.g. steering-angle sensor, lateral
acceleration sensor) from which the corresponding lock activations are obtained. In this way the optimum power is
distributed to the drive wheels.
Centre-differential lock (in the transfer box): Distributes the moment released by the gear via the cardan
shafts to the front axle final drive or rear axle differential.
Rear-differential lock (depending on the equipment in the rear final drive): Distributes the moment to the two
rear driving wheels.
Porsche Traction Management, or PTM, is a system which guarantees or improves the traction of the vehicle.
Two locks available in the system can be activated.
It operates permanently and receives values from different sensors (e.g. steering-angle sensor, lateral
file://E:\POSES\data\rl\2\9PA\4604878_KDNum_0.htm 5/19/2011
Information Page 3 of 3
acceleration sensor) from which the corresponding lock activations are obtained. In this way the optimum power is
distributed to the drive wheels.
Centre-differential lock (in the transfer box): Distributes the moment released by the gear via the cardan
shafts to the front axle final drive or rear axle differential.
Rear-differential lock (depending on the equipment in the rear final drive): Distributes the moment to the two
rear driving wheels.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\4604878_KDNum_0.htm 5/19/2011
Technical data Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
39 Technical data - as of MY 2003
- Technical data on transfer box
- Technical data on four-wheel final drive
- Technical data on rear final drive
Installation Location:
Type: Z 48.20
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Technical data Page 3 of 6
Type: Z 48.00
Type: Z 48.50
Installation Location:
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Technical data Page 4 of 6
Type: V 48.20
Type: V 48.00
Type: V 48.50
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Technical data Page 5 of 6
Installation Location:
Type: H 48.20
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Technical data Page 6 of 6
Type: H 48.00
Type: H 48.50
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\4634860_KDNum_Tkt_0.htm 5/19/2011
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Notes
Note
The clutch system and brake system share a common reservoir.
The clutch slave cylinder is located to the left of the transmission, at the top of the clutch bell-housing.
Observe brake fluid quality. Use only new DOT 4 brake fluid.
The brake fluid change interval is 2 years in conjunction with Super DOT 4 brake fluid.
This brake fluid is available under the following part numbers: Container quantity: 1 litre = 000.043.203.66. 30
litres = 000.043.203.67.
The shared reservoir for the brake and clutch systems is located in the
engine compartment, on the left under the cowl panel cover -arrow- in the
plenum panel.
1. Open the reservoir and connect the bleeding device → see figure . Switch on the bleeding device and set the
bleeding pressure to approx. 2.0 bar.
4. Open the bleeder valve -arrow- (approx. three turns!) until brake fluid
emerges. Press the clutch pedal three times and wait for approx. 30
seconds. Press the clutch pedal three times again (2 workers
required).
6. Tighten the bleeder valve to the specified tightening torque (3.5 ± 0.5)
ftlb.) and remove the bleeder hose from the clutch slave cylinder. Fit
dust cap and remove bleeder hose from reservoir.
7. Screw cap on reservoir. Once the vehicle has been filled and bled, the
brake fluid level in the reservoir must be between the MIN and MAX
markings. Adjust the brake fluid level if necessary. → see figure
8. Fit engine guard → 108019 Removing and installing engine guard.
9PAAD7, 9PAAE7
as of MY 2003
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Note
For better accessibility, remove the lower cover on the driver's side under the steering column.
1. Move the driver's seat back. Pull the steering wheel all the way out and put it in the highest position (better
access to pedals).
2. Remove and install cover under dashboard. → 702219 Removing and installing cover under dashboard
3. Remove and install trim panel under dashboard. → 701919 Removing and installing trim panel under
dashboard
Removing
Overview of pedals
1- Seal
2- Hexagon nut
3- Mounting saddle
4- Pin
5- Hexagon nut
6- Hexagon-head bolt
7- Seal
8- Fixing clip
9- Master cylinder
10 - Mounting
11 - Bolt
12 - Clutch pedal
13 - Cap
14 - Lock (mechanical)
15 - Clutch power spring
16 - Bearing shell
17 - Rubber stop
18 - Lock (mechanical)
19 - Pin
20 - Lock (mechanical)
21 - Mounting saddle for clutch pedal
22 - Switch
23 - Switch
5. The left lock remains on the pin (clutch pedal shaft). -arrow- Push the pin all the way to the left. If necessary,
release and lay aside the wiring harness. -Item 18, 19-
Right lock on pin, clutch pedal Left lock of clutch power spring
6. Detach pushrod of master cylinder from pedal. To do this, insert the pliers T10206 into cut-outs on clutch
pedal. Remove clutch pedal. -Item 12-
23
1- Seal
2- Hexagon nut
3- Mounting saddle
4- Pin
5- Hexagon nut
6- Hexagon-head bolt
7- Seal
8- Fixing clip
9- Master cylinder
10 - Mounting
11 - Bolt
12 - Clutch pedal
13 - Cap
14 - Lock (mechanical)
15 - Clutch power spring
16 - Bearing shell
17 - Rubber stop
18 - Lock (mechanical)
19 - Pin
20 - Lock (mechanical)
21 - Mounting saddle for clutch pedal
22 - Switch
23 - Switch
1. When the clutch pedal locks into place, the lugs on the right and left
must click in audibly. To do this, push the clutch pedal firmly in the
direction of travel on the mounting. -Position 10- Now turn the pedal
to the right and left (2 x click). → Locking the clutch pedal into place
4. The lock must be able to be inserted in the right groove. → Locks for clutch pedal pins
Clutch power spring Locks for clutch pedal pins
5. Insert clutch power spring. → Clutch power spring Insert the bolt in the correct position so that the hexagon
cannot twist. The lock must be inserted into the groove from the bolt.
6. Press the clutch pedal and the swivel the clutch power spring 180° to
the front and insert in the bearing. -arrows- Remove cotter pin.
Subsequent work
2. → 702219 Removing and reinstalling cover under dashboard diagnostic socket, clip in the connector.
9PAAD7, 9PAAE7
as of MY 2004
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Note
The clutch master cylinder is installed under the brake booster, accessible from the plenum panel in the engine
compartment.
2. Open bonnet and position it with the bonnet stay 9704 → 664419 Removing and installing cowl panel
cover .
3. Remove engine design cover → 700219 Removing and installing front cover (engine compartment).
4. Remove cowl panel cover → 664419 Removing and installing cowl panel cover.
6. Partly remove fuse carrier, including six connectors, on the left in the
plenum panel and lay to one side -arrow- → 9784 fuse carrier.
Warning notes
ATTENTION
Increased risk of accidents when working with brake fluid.
Possible danger of damage or injury.
Brake fluid on electrical contacts (even thinned brake fluid) leads to corrosion and may cause faults
in the system.
Removing
Overview of pedals
Overview of pedals excluding stop light switch
-1- - Seal
-2- - Hexagon nut
-3- - Mounting saddle
-4- - Pin
-5- - Hexagon nut
-6- - Hexagon-head bolt
-7- - Seal
-8- - Fixing clip/screw
-9- - Master cylinder
-10- - Mounting
-11- - Bolt
-12- - Clutch pedal
-13- - Cap
-14- - Lock (mechanical)
-15- - Clutch power spring
-16- - Bearing shell
-17- - Rubber stop
-18- - Lock (mechanical)
-19- - Pin
-20- - Lock (mechanical)
-21- - Mounting saddle for clutch pedal
-22- - Switch (clutch pedal switch)
-23- - Switch (interlock)
Note
Brake fluid is hygroscopic! Seal all lines immediately with suitable plugs.
Brake fluid will flow from the lines. Protect body in the area under the clutch master cylinder (e.g. with a cleaning
cloth).
2. Loosen pressure line from clutch master cylinder to slave cylinder -A- . To do this, remove safety clip to the
stop using a screwdriver -direction of arrow- .
Opening safety clip for pressure line Removing safety clip for pressure line
connection of clutch master cylinder connection from clutch master cylinder
3. Open safety clip. The pressure line can now be pulled off -arrow- .
4. Remove lines on brake fluid reservoir and clutch master cylinder -B- (pull strongly!).
Installing
Note
Use a new line from the brake fluid reservoir to the clutch slave cylinder.
If the switches -22 - 23- have been removed from the mounting saddle of the clutch pedal -21- they must be
replaced and their operation checked.
Overview of pedals
Overview of pedals excluding stop light switch
1- Seal
2- Hexagon nut
3- Mounting saddle
4- Pin
5- Hexagon nut
6- Hexagon-head bolt
7- Seal
8- Fixing clip/screw
9- Master cylinder
10 - Mounting
11 - Bolt
12 - Clutch pedal
13 - Cap
14 - Lock (mechanical)
15 - Clutch power spring
16 - Bearing shell
17 - Rubber stop
18 - Lock (mechanical)
19 - Pin
20 - Lock (mechanical)
21 - Mounting saddle for clutch pedal
22 - Switch (clutch pedal switch)
23 - Switch (interlock)
4. Connect line between brake fluid reservoir and clutch master cylinder
(top and bottom).
5. Fill brake fluid reservoir with brake fluid. The brake fluid level must
not exceed the MAX mark.
Subsequent work
3. Fit cowl panel cover → 664419 Removing and installing cowl panel
cover.
Note
If clutch switches 22-23 on the mounting saddle for clutch pedal 21 have been removed, they must be replaced.
Afterwards check operation of new clutch switches.
Check operation of both clutch switches -22-23- (see below: first switch (clutch pedal switch), second switch
(interlock).
1- Seal
2- Hexagon nut
3- Mounting saddle
4- Pin
5- Hexagon nut
6- Hexagon-head bolt
7- Seal
8- Fixing clip/screw
9- Master cylinder
10 - Mounting
11 - Bolt
12 - Clutch pedal
13 - Cap
14 - Lock (mechanical)
15 - Clutch power spring
16 - Bearing shell
17 - Rubber stop
18 - Lock (mechanical)
19 - Pin
20 - Lock (mechanical)
21 - Mounting saddle for clutch pedal
22 - Switch (clutch pedal switch)
23 - Switch (interlock)
Connect System Tester and select >> PSM << system. In the menu >> Input signals/clutch switches << read out
the switch states.
Now the switch (clutch switch) must switch to >> Actuated << .
If the switch (clutch pedal switch) does not operate, the installation
position must be checked. If that does not succeed, then follow the
troubleshooting procedure in the Technical Manual >> Group 0,
Diagnostic Repair Group 40-66, PSM Fault Code 650 << .
Connect System Tester and select >> Kessy << system. In the menu >>
Input signals/clutch switches (interlock) << read out the switch states.
Up to that point the switch (interlock) must be at >> Not actuated << in the System Tester.
If the switch (interlock) does not switch over, the installation position must be checked. If that does not succeed,
then follow the troubleshooting procedure in the Technical Manual >>
Group 0, Diagnostic Repair Group 91-97, Kessy Fault Code 650 << .
9PAAD7, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
2. Remove engine guard. → 108019 Removing and installing engine guard - chapter on "removing"
Technical values
Tightening torques
Installation Location:
The clutch slave cylinder -arrow- is located to the left of the transmission,
at the centre section of the clutch bell-housing (shown here on removed
transmission).
Note
Once the lead is separated from the clutch slave cylinder, the clutch
pedal must not be pressed until re-installation is complete.
During removal, do not bend the clutch slave cylinder more than 3°
from the installation position. Greater deflections of the pushrod can
damage the clutch slave cylinder and cause brake fluid to run into the
bellows.
1. Unclip the line -arrow- on the clutch slave cylinder (remove retaining
spring) and seal using a suitable plug. Pay attention to the seal on
the line. This can remain stuck in the clutch slave cylinder. Carefully
remove the seal and replace with a new one, if necessary.
3. Press the clutch slave cylinder carefully outwards -Arrow 1- . During removal, do not bend the clutch slave
cylinder more than 3° from the installation position.
4. Remove the clutch slave cylinder to the rear -Arrow 2- without tilting it. Wipe off any emerging brake fluid
with a lint-free cloth.
Installation Location:
Note
Drain the clutch slave cylinder fully before installation. Check the bellows for ingress of fluid and clean with a
lint-free cloth if necessary.
Pay attention to the seal of the clutch slave cylinder. This may have been left behind in the clutch slave
cylinder during removal.
During installation, do not bend the pushrod of the clutch slave cylinder more than 3° from the installation
position. Greater deflections of the pushrod can damage the clutch slave cylinder.
Make sure the clutch slave cylinder is positioned correctly during installation.
Check that the pushrod of the clutch slave cylinder is definitely centred in the release lever.
1. Remove the seal from the clutch slave cylinder and fit it in the correct position on the line. Use a new seal, if
necessary.
2. Insert the clutch slave cylinder carefully (do not tilt) and mount with
the fastening screw. Tightening torque: 17 ± 1.5 ftlb.
3. Remove the plug from the line and clip the line into the clutch slave
cylinder. Ensure the retaining spring is seated correctly.
Subsequent work
9PAAD7, 9PAAE7
as of MY 2003
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Removing clutch
ATTENTION
Clutch grabbing
Clutch pressure plate may warp if screws are not loosened and
tightened evenly.
→ Loosen and tighten the clutch pressure plate in the specified order.
Installing clutch
Installing clutch
Note
When installing the clutch plate, observe the correct installation position. Please note marking -arrow inset- on
clutch plate.
Note
Clutch plate marking Centring the coupling plate
If the marking -arrow- for the clutch adjuster no longer lines up after
reassembly, the clutch must be replaced.
Note
The clutch pressure plate must be positioned on the three dowel pins
→ Fitting clutch plate of the double-mass flywheel.
1. Position clutch plate and pressure plate on engine using special tool
centring mandrel 3434 -arrow- .
Note
Replace clutch fastening screws.
Note
If the marking -arrow- for the clutch adjuster no longer lines up after reassembly, the clutch must be
replaced.
ATTENTION
Danger of injury from releasing clutch set.
Due to preloading of the clutch set, parts of the coupling may fly
out.
Note
When installing the clutch plate, observe the correct installation position.
Please note marking -arrow inset- on clutch plate.
Note
The clutch pressure plate must be positioned on the three dowel pins
→ Fitting clutch plate of the double-mass flywheel.
ATTENTION
Danger of injury from releasing clutch set.
Due to preloading of the clutch set, parts of the coupling may fly
out.
3. Unscrew locking hook with special tool 2-hole nut turner 3212 in an
anti-clockwise direction -arrow- and remove it. Removing locking hooks
9PAAD7, 9PAAE7
as of MY 2003
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1. Measure clutch wear at one of the three clutch adjusters. To do this, measure using material 00000 between
adjuster and clutch pressure plate -arrow inset- .
Clutch is OK:
Clutch is defective:
9PAAD7, 9PAAE7
as of MY 2003
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
WARNING
Risk of scalding from hot oil
Note
Secure vehicle to prevent it rolling away. Oil inspection plug
2. The oil level is correct if the oil reaches the lower edge of the inspection window.
If this is not the case, add more transmission oil. → 340135 Checking and topping up transmission oil -
chapter on "refilling"
WARNING
Risk of scalding from hot oil
Note
Use only oil approved by Porsche.
Oil inspection plug
2. Fill in oil using oil filler for ATF up to lower edge of oil inspection plug -arrow- .
3. Screw in oil inspection plug -arrow- with new sealing ring. → Tightening torque: 26 ftlb.
Subsequent work
9PAAD7, 9PAAE7
as of MY 2003
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
WARNING
Risk of scalding from hot oil
Note
Secure vehicle to prevent it rolling away. Oil drain plug
3. Screw in oil drain plug -arrow- with new sealing ring. → Tightening torque: 26 ftlb.
Note
Use only oil approved by Porsche.
5. Fill in oil using oil filler for ATF up to lower edge of inspection
window -arrow- . → Change quantity: 1.8 litre
Subsequent work
9PAAD7, 9PAAE7
as of MY 2003
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
2. Unscrew fastening screws on centre console cover -right arrows- , tip cover up and back -curved arrow-
and separate cable connection -inset- .
Leather boot Centre console cover
3. Press leather boot out of centre console cover from below -arrows- .
4. Unlock shift-lever knob. To do this, turn the grooved end piece on the
gearshift lever clockwise by a quarter of a turn until it engages.
Note
Do not pull shift-lever knob off by pulling on the leather boot.
Installation Location:
Overview of shift-lever knob
4. Position cable connection -inset- on the underside of the centre console cover.
5. Tip centre console cover backwards -curved arrow- and screw in fastening screws -right arrows- .
9PAAD7, 9PAAE7
as of MY 2003
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
1. Remove shift lever knob. → 340419 Removing and installing shift lever knob - chapter on "removing"
Foam mat
3. Lock gearshift lever in neutral position using special tool locking
bridge 9619 -arrow- .
ATTENTION
Plate on fastening part breaks off.
5. Pull shift and selector cable off gearshift bracket. To do this, release
the fastening parts using a screwdriver -arrows- .
6. Remove special tool locking bridge 9619. Removing shift and selector cables
Gearshift bracket
Note
Transmission must be in neutral position!
1. Install top section of gearshift bracket. Insert shift and selector cable
into fastening part -arrows- .
Gearshift bracket
3. Lock shift and selector cable by pressing on the fastening parts -arrows- .
Foam mat
1. Install shift lever knob. → 340419 Removing and installing shift lever knob - chapter on "installing"
9PAAD7, 9PAAE7
as of MY 2003
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
2. Remove rear cardan shaft. → 393519 Removing and reinstalling rear cardan shaft - chapter on
"Removing" [9PAAE7]→ 393519 Removing and reinstalling rear cardan shaft - chapter on
"Removing" [9PAAD7]
3. Remove top section of gearshift bracket. → 340819 Removing and reinstalling top section of gearshift
bracket - chapter on "Removing"
Installation Location:
2. Remove front cardan shaft on the transfer box and tie it up at the side -arrow- .
Catalytic converter
6. Unscrew four screws -A- on transmission cross member.
9. Release shift and selector cable attachment using disassembly tool, universal 21 on gearshift lever
-arrows- .
10. Guide the shift and selector cables out of the support.
11. Remove bottom section of gearshift bracket with installed shift and
selector cables backwards over the transfer box → Removing bottom
section of gearshift bracket .
Note
If present: remove assembly aids from production -arrow- . These were only needed for the first installation
in order to align the gearshift bracket.
1. Insert shift and selector cables in bottom section of gearshift bracket
-1st arrow- , then fit safety clips -2nd arrow- .
Note
Screws which are tightened with a torque angle must be replaced
with new ones.
Note
Screws which are tightened with a torque angle must be replaced
with new ones.
9. Fix front cardan shaft to transfer box with new screws. → Initial
tightening: 22 ftlb. → Final tightening: 90 °
Catalytic converter
Mount of gearshift bracket to body
10. Screw in threaded joint on bottom section of gearshift bracket -arrows- . → Tightening torque: 18 ftlb.
Subsequent work
1. Install rear cardan shaft. → 393519 Removing and reinstalling rear cardan shaft - chapter on
"Installing" [9PAAE7]→ 393519 Removing and reinstalling rear cardan shaft - chapter on
"Installing" [9PAAD7]
2. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
3. Install top section of gearshift bracket. → 340819 Removing and reinstalling top section of gearshift bracket -
chapter on "Installing"
9PAAD7, 9PAAE7
as of MY 2004
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
2. Remove centre console cover. → 681719 Removing and installing centre console - "Removing" chapter
3. Remove shift lever knob. → 340419 Removing and installing shift lever knob - chapter on "removing"
4. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
5. Remove rear cardan shaft. → 393519 Removing and reinstalling rear cardan shaft - chapter on "Removing"
6. Remove front cardan shaft. → 390219 Removing and installing front cardan shaft - chapter on "Removing"
7. Remove clutch slave cylinder. → 303019 Removing and installing clutch slave cylinder - "Removing" chapter
Removing transmission
Removing transmission
Note
The cables do not have to be separated from the transmission in order to remove the transmission.
2. Unscrew fastening screws for securing bottom section of gearshift bracket to body.
4. Unscrew coolant pipe support threaded joint on the transmission bell housing.
7. Remove transfer box → 396519 Removing and installing transfer box - chapter on "Removing".
11. Push out transmission. Pull off vent line for the transfer box.
13. Remove shift and selector cables from support using special tool removal tool, universal nr.21. Remove
Fastening points for securing Plate
transmission to engine
Removal
Installing transmission
Installing transmission
Note
If present: Remove assembly aids from production on the bottom section of the selector console -arrow- .
These were only needed for the first installation in order to align the shift console.
Assembly aid on bottom section of
gearshift bracket
1. Fasten the shift and selector cables to the ball head joint on the
support.
Assembly of circlips
3. Raise manual transmission with special tool plate and transmission
jack .
Supporting transmission
7. Remove special tool plate 9725.
Plate
8. Install breather pipe. To do so, screw in the fastening screws -1,2- on
the transmission. → Tightening torque: 17 ftlb. → Tightening
torque: 6.5 ftlb.
2. Install front cardan shaft. → 390219 Removing and installing front cardan shaft - chapter on "Installing"
3. Install rear cardan shaft. → 393519 Removing and reinstalling rear cardan shaft - chapter on "Installing"
4. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
5. Install shift lever knob. → 340419 Removing and installing shift lever knob - section on "Installing"
9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work for removing the transmission
1. Remove engine. → 100121 Removing engine
Removing transmission
Removing transmission
Disassembly of circlips
2. Remove shift and selector cables from support using special tool
removal tool, universal nr.21. Remove selector support with
cables.
5. Raise transmission a few centimetres and notch transmission cross member. -A-
Transmission cross member Transmission to workshop crane
6. Unscrew fastening screws for securing transmission to engine.
Disassembly of circlips
2. Remove shift and selector cables from support using special tool
removal tool, universal nr.21. Remove selector support with
cables.
7. Remove transmission
Refitting transmission
1. Refit the transfer box onto the transmission.
2. Fasten the shift and selector cables to the ball head joint on the
support.
Assembly of circlips
4. Connect the vent line for the transfer box on the transmission.
Note
Screws which are tightened with a torque angle must be replaced with new ones.
Transmission to engine threaded joint Transmission to workshop crane
point
8. Raise transmission a few centimetres and install transmission cross
member on support. -A- → Initial tightening: 37 ftlb. → Final
tightening: 90 °
Subsequent work
9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Technical data
Transmission ratios
1. gear4.68
2. gear2.53
3. gear1.69
4. gear1.22
5. gear1.00
6. gear0.84
Reverse gear4.27
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
Overview of cap
1. Drive two small holes -figure- - offset by 180 degrees - into the
sealing ring.
Installation Location:
Overview of cap
1. Drive new cap in flush using special tool pressure piece t10180.
2. Check transmission oil . → 340135 Check and top up transmission oil - Chapter "Checking"
9PAAD7, 9PAAE7
as of MY 2003
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Clutch lever
Guide tube screws
2. Remove guide tube for release bearing. To do this, unscrew four fastening screws -arrow- .
Note
There are two depressions in the sealing ring -arrows- . The
sheetmetal screws for removing the sealing ring are screwed in here.
1. Fill the space between the dust and sealing lips on the new sealing ring with grease).
2. Drive new sealing ring in flush with special tool pressure piece t10180.
3. Install guide tube for release bearing. To do this, screw in four fastening screws -arrow- .
Guide tube screws Preparing sealing ring
Clutch lever
4. Install clutch lever with release bearing. To do this, the retaining spring -arrow- must be engaged in the
opening in the clutch lever.
9PAAD7, 9PAAE7
as of MY 2003
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
Overview of output-shaft sealing ring
Note
There are two depressions in the sealing ring. -arrows- The
sheetmetal screws for removing the sealing ring are screwed in here.
1. Fill the space between the dust and sealing lips on the new sealing
ring with grease).
4. Remove special tool protective sleeve t10186 and drive sealing ring in flush using special tool pressure
Installing sealing ring Protective sleeve on output shaft
piece t10180 -arrow- .
Subsequent work
2. Check transmission oil. → 340135 Checking and topping up transmission oil - chapter on "Checking"
9PAAD7, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
2. Remove longitudinal interlock servo motor. → 397719 Removing and installing rear-differential lock servo
motor - "Removing" section
Removing rear final drive
Installation Location:
2. Loosen fastening screws for fixing cardan shaft centre bearing holder
to body.
Note
The colour marking, match point, on the cardan shaft and on the
flange of the rear final drive must be installed in alignment -arrows- .
This will neutralise the residual imbalance of the components.
Note
To loosen the cardan shaft on the rear axle transmission, a second
fitter should counter the fastening screws on the triangular flange of
the transfer box. Match points on the cardan shaft
4. Remove cardan shaft from rear axle transmission and tie it up.
Note
To loosen the drive shaft bolts on the rear axle transmission, a
second fitter should sit in the vehicle and block the rear-axle final
drive by actuating the foot brake.
8. Tip drive flange upwards -arrow- and gradually drain rear axle transmission. Remove bleeder line at the
same time.
Note
Screws which are tightened with a torque angle must be replaced
with new ones.
Note
The colour marking, match point, on the cardan shaft and on the flange of the rear final drive must be
installed in alignment -arrows- . This will neutralise the residual imbalance of the components.
1. Secure rear axle transmission on transmission jack with retainer
band.
Note
To tighten the drive shaft bolts on the rear final drive, a second fitter
should sit in the vehicle and block the rear-wheel drive assembly by
actuating the foot brake.
ATTENTION
Cardan shaft can be damaged by imbalance.
To attach the cardan shaft to the rear final drive, a second fitter should counter the fastening screws on the
triangular flange of the transfer box.
6. Screw in fastening screws for fixing cardan shaft centre bearing holder to body. → Tightening torque: 44
ftlb.
Note
Centre bearing must be installed without tension.
Alignment of special tool 9680 Cardan shaft support to body
Fit special tool centring tool 9680 -Werkzeug in Einbaulage- in the
order specified.
2. Install servo motor for rear-differential lock. → 397719 Removing and installing rear-differential lock servo
motor - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
To unscrew the cardan shaft bolts, a second fitter should sit in the
vehicle and block the drive train by actuating the foot brake.
The colour markings, match points -arrows- on the cardan shaft and
on the all-wheel final drive flange must be aligned. This will neutralise
the residual imbalance of the components.
1. Detach cardan shaft from final four wheel drive → Front cardan shaft to all-wheel final drive .
Match points of front cardan shaft to
front final drive
Note
To unscrew the cardan shaft bolts, a second fitter should sit in the
vehicle and block the drive train by actuating the foot brake.
The colour markings, match points -arrows- on the cardan shaft and
on the all-wheel final drive flange must be aligned. This will neutralise
the residual imbalance of the components.
2. Remove cardan shaft from the transfer box → Front cardan shaft to
transfer box .
3. Swivel the cardan shaft forwards over the suspension subframe and
remove it.
Note
To tighten the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive train by actuating
the brake.
Screws which are tightened with a torque angle must be replaced with new ones.
Note
The colour markings, match points -arrows- on the cardan shaft and
on the all-wheel final drive flange must be aligned. This will neutralise
the residual imbalance of the components.
1. Swivel the cardan shaft over the suspension subframe and install it.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
39 13 19 Removing and installing transfer box control module - as
of MY 2003
- Removing transfer box control module
- Installing transfer box control module
Installation Location:
Note
The control unit is located under the right front seat.
1. The ignition key must be removed before removing the connector from the control unit.
2. Move right front seat all the way back and up.
3. For vehicles with a telephone, remove the telephone control unit. → 919019 Removing and installing control
unit for telephone - chapter on "removing"
8. Release the two connectors -A- and pull them off -B- .
Installation Location:
1. Insert the control unit -A- until the locking tabs -B- are felt to engage.
2. Insert the two connectors -A- and press in the locking mechanism -B- until it is felt to engage.
3. Place the support with the two control units in the installation position -C- .
4. Move seat all the way back
and tighten the support with
the fastening screw.
Note
Only for vehicles with telephone
5. Position the support for the telephone control unit and screw down
using the three fastening nuts.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
Overview of sealing rings
1. Remove output flange with special tool striker vw 771/1 and shop-
made tool .
Installation Location:
Overview of sealing rings
Replacing circlip
2. Drive in new sealing ring with special tool pressure piece t10181
until the special tool touches the transmission housing.
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Marking the position of the cardan shaft with respect to the transfer box triangular flange serves only to
prevent possible humming noises.
Note
To loosen the cardan shaft on the rear axle transmission, a second
fitter should counter the fastening screws -arrows- at the triangular
flange of the transfer box.
2. The position of the cardan shaft -arrows- with respect to the rear axle transmission flange is marked with a
white dot, match point, on both components.
Note
The colour marking, match point, on the cardan shaft and on the rear final drive flange must be aligned. This
will neutralise the residual imbalance of the components.
3. Mark the position of the
cardan shaft -arrow- with
respect to the transfer box
flange with a coloured pen.
Mark for rear cardan shaft to transfer Match points for cardan shaft to final
box drive
4. Loosen fastening screws -arrow- securing cardan shaft support to
centre bearing.
ATTENTION
Noises caused by damage in the drive line
7. Release cardan shaft centre bearing holder. To do this, unscrew six fastening screws -arrows- .
Note
To prevent the cardan shaft from being damaged, a second mechanic
is required to remove the equipment.
Installation Location:
Overview of rear cardan shaft
ATTENTION
Cardan shaft can be damaged if not handled correctly
ATTENTION
Leakage due to damage to centring sleeve
Note
There is no colour marking on the flange to the transfer box for installing new components, transfer box or
cardan shaft. As a result, positioning is not an issue.
If none of the components are replaced, the mark you apply is a precautionary measure in order to avoid
humming noises from the drive line.
Note
To prevent the cardan shaft from being damaged, a second mechanic is required to install the equipment.
2. Pull cardan shaft joints apart so that they sit in the transmission flanges.
3. Screw in six screws -arrow- on the centre bearing holder but do not
tighten.
Note
The colour marking, match point -arrow- , on the cardan shaft and on the flange of the rear final drive must
be aligned. This will neutralise the residual imbalance of the components.
Note
To attach the cardan shaft to the rear axle transmission, a second
fitter should counter the fastening screws on the triangular flange of
the transfer box.
5. Screw in new screws for cardan shaft flange at the rear axle
transmission. → Initial tightening: 22 ftlb. → Final tightening: 90 °
Match points for cardan shaft to final
drive
6. Tighten bolts connecting cardan shaft triangular flange to transfer
box -arrows- . Counter with an open-ended wrench. → Tightening
torque: 56 ftlb.
Note
Centre bearing must be installed without tension.
Subsequent work
Subsequent work - rear cardan shaft
1. Install the exhaust system. → 260119 Removing and installing exhaust system - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
striker commercially vw
available tool 771/1
2. Remove front cardan shaft → 390219 Removing and installing front cardan shaft - chapter on
"Removing" [9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on
"Removing" [9PAAD1 9PAAD7 9PAAE7].
Installation Location:
Marking nut
2. Determine rolling moment of axle transmission with special tool
torque screwdriver for measuring friction moment 89. Push stop
on special tool to zero and turn transmission several times. Note the
displayed value.
Installation Location:
Marking nut
Location Explanation Type Basic value Tolerance 1 Tolerance 2
Rolling moment Adjustment value 2.0 (1.5 ftlb.) Nm +0.5 (0.5 ftlb.) Nm
2. Carry out oil check. → 399035 Checking and topping up oil for all-wheel final drive - chapter on "Checking"
3. Install engine guard → 108019 Removing and installing engine guard - chapter on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
Overview of left sealing ring
1. Remove flanged shaft with special tool striker vw 771/1 and shop-
made tool .
Installation Location:
Overview of right sealing ring
1. Remove flanged shaft with special tool striker vw 771/1 and shop-
made tool .
Installation Location:
Overview of right sealing ring
Replacing circlip
2. Check oil for four-wheel final drive. → 399035 Checking and topping up oil for four-wheel final drive - chapter
on "Checking"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Mark rubber mounting for transmission housing at the installation position -arrow- .
Removing rubber mounting, drive side Marking for rubber mounting
2. Position special tool assembly fixture 9716 a/b on rubber mounting → Removing rubber mounting, drive
side .
Removing rubber mounting for four-wheel final drive, right output side
Installation Location:
1. Mark rubber mounting for transmission housing at the installation position -arrow- .
2. Position special tool assembly fixture 9716 a/b on rubber mounting → Removing right rubber mounting .
Removing rubber mounting for four-wheel final drive, left output side
Installation Location:
Removing right rubber mounting Marking for rubber mounting
Installation Location:
Note
Noises in drive line
3. Pull in rubber mounting in direction of travel until installation position is reached. Measure distance between
Installation position of rubber mounting
assembly fixture ring and housing using workshop caliper gauge 139. → Distance: 7.5 mm +/-0.1 mm
Installing rubber mounting for four-wheel final drive, right output side
Installation Location:
Note
Noises in drive line
Installation position of mount in housing is incorrect Pay attention to installation dimension of mount to
housing
1. Mark centre of bulge in rubber mounting → Marking for centre of rubber mounting .
Installation Location:
Rubber mounting for left output side -3-
Note
Noises in drive line
Installation position of rubber mounting bulge is incorrect Rubber mounting bulge must be installed vertically
into housing
Installation position of mount in housing is incorrect Pay attention to installation dimension of mount to
housing
2. Position special tool assembly fixture 9716 a/b/c on rubber mounting → Positioning bearing .
Positioning bearing
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Installation Location:
Rubber mounting, drive side -1-
Installation Location:
Rubber mounting for output side -2-
Installation Location:
Note
Noises in drive line
Installation Location:
Note
Noises in drive line
Note
Noises in drive line
Installation position of rubber mounting bulge is incorrect Rubber mounting bulge must be installed vertically
into housing
Installation position of mount in housing is incorrect Pay attention to installation dimension of mount to
housing
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
Overview of removing and installing transfer box
Note
To unscrew the cardan shaft bolts, a second fitter should sit in the
vehicle and block the drive train by actuating the foot brake.
1. Remove front cardan shaft on the transfer box and tie it up.
Note
Always observe the exact work sequence when installing/removing the
transmission cross member.
6. Unscrew two transmission cross member screws -B- on transfer box holder.
7. Place a wooden block -arrow- between the converter bell housing and suspension subframe.
Supporting transmission Transmission cross member
8. Unscrew fastening nut and push holder with Tiptronic line -A- away to the side.
11. Gradually drain transfer box. Pull out vent line -arrows- and remove it from the retainers on the upper side.
Supporting transmission
2. Gradually run in transfer box. Press vent line into holder -arrow- and
attach to transfer box.
Note
Always observe the exact work sequence when installing/removing the
transmission cross member.
Note
Screws which are tightened with a torque angle must be replaced
with new ones. Supporting transmission
Note
Screws which are tightened with a torque angle must be replaced with new ones.
9. Connect front cardan shaft to transfer box. → Initial tightening: 22 ftlb. → Final tightening: 90 °
10. Connect cable plugs -1 , 2- to
the transfer box and secure
the cable holder.
2. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
2. Pull off fastening element -arrow- for cable lead and place lead aside.
ATTENTION
Emerging oil is harmful to the eyes.
Note
Avoid minor oil leaks when removing the servo motor. Servo motor fastening
Installation Location:
Overview of transverse lock servo motor
Subsequent work
Electric plug on servo motor Cable lead fastening
Subsequent work for servo motor for differential lock
1. Check the oil in the final drive. → 399035 Checking and topping up oil for rear final drive
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
1. Before beginning to work on the servo motor for the transfer box, engage the Low Range offroad driving
program.
2. Disconnect Low Range cable plug -arrow- on the servo motor and loosen cable holder -A- .
Low Range cable plug
3. Pull centre-differential lock cable plug -arrow- off the servo motor.
Installation Location:
Overview of servo motor
Note
If a new servo motor is installed, it is supplied in Low Range position,
offroad driving program.
1. Connect servo motor to the shaft on the transfer box. Position cutout
of the shaft -right inset- to the servo motor -left inset- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
striker workshop VW
equipment 771/1
Installation Location:
Note
A second fitter is required for loosening/tightening the flange
3. Unscrew nut on drive flange.
To do this, block flange with
special tool arm bracket
3435.
Installation Location:
Overview of cardan flange sealing ring
Note
A second fitter is required for loosening/tightening the flange
3. Position marking on nut and drive shaft -arrow- again so that the
rolling moment determined prior to removal is reached once again.
Note
If the rolling moment has to be corrected, this should be done via the tightening torque of the nut.
4. Check rolling moment with special tool torque screwdriver for measuring friction moment NR.89. →
Rolling moment: 2.0 ftlb. -0.2 ftlb. +0.2 ftlb.
Checking rolling moment
2. Check the oil in the final drive. → 399035 Inspecting and adding oil for rear final drive - chapter on
"Checking"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
2. Support engine. → Support engine on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ Support engine on
the body [9PAAD1 9PAAD7] or → Supporting engine on the body [9PAAD1 9PAAD7]→ Supporting engine
on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
3. Remove front wheels. → 440519 Remove and install wheel - Chapter "Removing"
4. Remove engine guard → 108019 Removing and installing engine guard - Chapter "Removing".
5. Remove front cardan shaft → 390219 Install and remove front cardan shaft - Chapter "Removing" [9PAAE1
9PAAF1 9PAAJ1]→ 390219 Install and remove front cardan shaft - Chapter "Removing" [9PAAD1 9PAAD7
9PAAE7].
Installation Location:
1. Clamp steering wheel in centre position with steering wheel holder -figure- .
3. Engage special tool spring compressor VW 552 in top of wheel housing, behind wheel housing liner, and
support the spring strut.
Wheel housing liner mount
9. Raise unit lifting platform until it bears against the front-axle carrier.
VAG bolts
Note
Fastening screw -left arrow- at front right cannot be removed until
the front-axle carrier is lowered.
VAG bolts
11. Undo bolt connecting spring strut to trailing arm -arrow- .
ATTENTION
Over-extension of drive shafts on running gear!
15. Lower front-axle carrier with the unit lifting platform. Remove vent line
from the final drive at the same time.
ATTENTION
Risk of damage to ATF lines and pressure line for power steering.
Note
A second fitter is required for removing/installing the four-wheel final Pressing out drive shaft
drive.
18. Tilt forward the transmission housing together with drive flange.
19. Remove four-wheel final drive downwards through the front-axle carrier.
Installation Location:
ATTENTION
Risk of damage to ATF lines and pressure line for power steering.
Note
A second fitter is required for removing/installing the four-wheel final drive.
3. Insert right drive shaft into output flange and place final drive into the
mounts on the front-axle carrier.
VAG bolts
Note
The front right fastening screw for the four-wheel final drive
-left arrow- can only be screwed in with the front-axle carrier
lowered.
5. Insert fastening screws -arrows- for four-wheel final drive and screw
for drive flange.
Note
Supports 1, 2 and 3 must be fitted to the unit lifting platform. VAG bolts
6. Raise front-axle carrier with unit lifting platform until it bears against the body. Position vent line at the same
time.
Note
For details of tightening torques for running gear parts, see Group 4
(Running gear) → 40 Tightening torques for front axle.
10. Engage servo line in the three holders -arrows- on the front-axle carrier.
11. Screw servo line holders -arrow- on to air-conditioning compressor and clip in the line.
Note
Screws which are tightened with a torque angle must be replaced with new ones.
Servo line holders Coolant pipe holders
Note
For details of tightening torques for running gear parts, see Group 4 (Running gear) → 40 Tightening
torques for front axle.
17. Remove special tool spring compressor VW 552 from spring strut.
Installation position of spring Cover plate on steering
compressor
18. Screw in plastic nuts -arrows- on front right wheel housing liner.
Note
For details of tightening torques for running gear parts, see Group 4 (Running gear) → 40 Tightening
torques for front axle.
2. Remove engine support. → Support engine on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ Support
engine on the body [9PAAD1 9PAAD7] or → Supporting engine on the body [9PAAD1 9PAAD7]
→ Supporting engine on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
3. Install right engine compartment cover → 700219 Remove and install front cover (engine compartment) -
Chapter "Installing".
4. Mount front wheels. → 440519 Remove and install wheel - Chapter "Installing"
5. Calibrate steering angle sensor → 456005 Initialise and calibrate steering angle sensor
7. Install engine guard → 108019 Install and remove engine guard - Chapter "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
WARNING
Risk of scalding from hot oil
Note
The vehicle must stand horizontally. Inspection/drain plug
Note
The oil level can only be checked after the vehicle has been idle for 45 minutes.
2. The oil level is correct if the oil reaches the lower edge of the inspection window.
Note
Use only oil approved by Porsche.
3. If this is not the case, top up the oil. → 399035 Inspecting and adding oil for transfer box - chapter on "Filling"
4. Screw in oil inspection plug -A- with new sealing ring. → Tightening torque: 15 ftlb.
WARNING
Risk of scalding from hot oil
Note
The oil level can only be checked after the vehicle has been idle for 45 Inspection/drain plug
minutes.
Note
The vehicle must stand horizontally!
Note
Use only oil approved by Porsche.
2. Fill with oil using the ATF filling device for filling transmission NR.161 to the lower edge of inspection
plug -A- . Raise filling device.
3. Screw in oil inspection plug -A- with new sealing ring. → Tightening torque: 15 ftlb.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
WARNING
Risk of scalding from hot oil
2. The oil level is correct if the oil reaches the lower edge of the
inspection window.
3. If this is not the case, top up the oil. → 399035 Inspecting and adding oil for rear final drive - chapter on
"Filling"
WARNING
Risk of scalding from hot oil
Note
Vehicle must be horizontal in order to fill rear final drive. Control/drain plug for rear final drive
2. Fill with oil using the ATF filling device for filling transmission NR.161 to the lower edge of inspection
plug -A- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
1. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
WARNING
Risk of scalding from hot oil
Note
Vehicle must be horizontal to check oil level in all-wheel final drive. Oil inspection plug-filler screw
1. Unscrew oil inspection plug -A- with tool special inserts mod. AB 170.
2. The oil level is correct if the oil reaches the lower edge of the inspection window.
3. If this is not the case, top up the oil. → 399035 Checking and topping up oil for all-wheel final drive - chapter
on "Filling"
4. Screw in oil inspection plug -A- with new sealing ring. To do this, use the special tool special inserts model
AB 170 and accessory for the torque wrench: open ring wrench insert a/f 13 + adapter 98-1. →
Tightening torque: 26 ftlb.
Topping up oil for four-wheel final drive
WARNING
Risk of scalding from hot oil
Note
Vehicle must be horizontal in order to fill final drive. Oil inspection plug-filler screw
1. Unscrew oil inspection plug -A- with tool special inserts mod. AB 170.
Note
Use only oil approved by Porsche.
2. Fill with oil using the ATF filling device for filling transmission 161 to the lower edge of inspection plug
-A- .
3. Screw in oil inspection plug -A- with new sealing ring. To do this, use
the special tool special inserts model AB 170 and accessory for
the torque wrench: open ring wrench insert a/f 13 + adapter 98-
1. → Tightening torque: 26 ftlb.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
WARNING
Risk of scalding from hot oil
3. Screw in oil drain plug -B- with a new sealing ring. → Tightening
torque: 26 ftlb. Oil inspection and drain plug
4. Unscrew oil inspection plug using the special inserts model AB 170
tool.
5. Using the ATF filling device for filling transmission 161, fill with oil
up to the lower edge of the oil inspection plug -A- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
WARNING
Risk of scalding from hot oil
3. Screw in oil drain plug -B- with new sealing ring. → Tightening torque: 26 ftlb.
WARNING
Risk of scalding from hot oil
Note
Vehicle must be horizontal in order to fill rear final drive.
5. Fill with oil using the ATF filling device for filling transmission 161 to the lower edge of inspection plug
opening -A- . → Tightening torque: 1.25 l +0.35 l
6. Screw in oil inspection plug -A- with new sealing ring. → Tightening
torque: 26 ftlb.
7. Check oil for rear final drive → 399035 Checking and topping up oil
for rear final drive - chapter on "Checking"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
WARNING
Risk of scalding from hot oil
Note
Vehicle must be horizontal in order to fill the transfer box.
Note
Use only oil approved by Porsche.
5. Fill with oil to the lower edge of the inspection plug opening -A- using
the ATF filling device for filling transmission 161. Raise filling Oil inspection and drain plug
device.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
striker commercially vw
available tool 771/1
Preliminary work sealing ring for transfer box
ATTENTION
Leakage due to scores on the sealing face.
→
When removing the sealing ring, place the tip of the hook on the sealing ring only and not on the sealing
Removing output flange Rubber ring for rear output drive
1. Drive in new sealing ring with special tool pressure piece T10185
until the special tool touches the transmission housing.
Note
Ensure that the round seal is
inserted.
Caulking nuts
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
striker commercially vw
available tool 771/1
3. Support transmission with material 00000 and secure with retaining band.
4. Unscrew four exhaust system screws on the cross member -centre arrow- and unscrew screw connection
holder on body -right arrow- .
Transmission cross member Exhaust system at cross member
6. Unscrew two screws on the cross member -B- on the transfer box holder and remove transmission cross
member.
Installation Location:
1. Unscrew collar nut of output flange with special tool socket t10204. To do this, block flange with special tool
arm bracket 3435.
3. Remove output flange with shop made tool and striker vw 771/1.
Round seal on output flange Countering flange
Installation Location:
Overview of sealing ring for front transfer box output
Note
Ensure that the round seal -arrow- is inserted.
1. Drive in new sealing ring with special tool pressure piece T10185
→ Driving in the sealing ring until the special tool touches the
transmission housing.
Round seal on output flange
2. Install output flange and, if necessary, drive in with a plastic hammer.
Note
Ensure that the round seal -arrow- is inserted.
Replace nut on output flange.
Caulking nuts
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
1. Remove transfer box. → 396519 Removing and installing transfer box - chapter on "Removing"
ATTENTION
Damage to input shaft bearing.
1. Using the bevelled attachment from the slide hammer kit 168, make
a small hole -figure- in the sealing ring.
1. Fill the space between the dust and sealing lips on the new sealing
ring with grease.
Subsequent work
2. Check oil for transfer box. → 399035 Check and top up oil for transfer box - Chapter "Checking"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
39 IN Information - as of MY 2003
Porsche Traction Management, or PTM, is a system which guarantees or improves the traction of the vehicle.
Two controllable locks are available in the system.
It operates permanently and receives values from different sensors (e.g. steering-angle sensor, lateral
acceleration sensor) from which the corresponding lock controls are obtained. In this way the optimum power is
distributed to the drive wheels.
Longitudinal lock (in the transfer box): Distributes the moment released by the gear via the cardan shafts to
the front or rear axle gear.
Longitudinal interlock (depending on the equipment in the rear final drive): Distributes the moment to the two
rear driving wheels.
Porsche Traction Management, or PTM, is a system which guarantees or improves the traction of the vehicle.
Two locks available in the system can be activated.
It operates permanently and receives values from different sensors (e.g. steering-angle sensor, lateral
acceleration sensor) from which the corresponding lock activations are obtained. In this way the optimum power is
distributed to the drive wheels.
Centre-differential lock (in the transfer box): Distributes the moment released by the gear via the cardan
shafts to the front axle final drive or rear axle differential.
Rear-differential lock (depending on the equipment in the rear final drive): Distributes the moment to the two
rear driving wheels.
Porsche Traction Management, or PTM, is a system which guarantees or improves the traction of the vehicle.
Two locks available in the system can be activated.
It operates permanently and receives values from different sensors (e.g. steering-angle sensor, lateral
acceleration sensor) from which the corresponding lock activations are obtained. In this way the optimum power is
distributed to the drive wheels.
Centre-differential lock (in the transfer box): Distributes the moment released by the gear via the cardan
shafts to the front axle final drive or rear axle differential.
Rear-differential lock (depending on the equipment in the rear final drive): Distributes the moment to the two
rear driving wheels.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
39 Technical data - as of MY 2003
- Technical data on transfer box
- Technical data on four-wheel final drive
- Technical data on rear final drive
Installation Location:
Type: Z 48.20
Type: Z 48.00
Type: Z 48.50
Installation Location:
Overall view of front-axle final drive
Type: V 48.20
Type: V 48.00
Type: V 48.50
Installation Location:
Type: H 48.20
Type: H 48.00
Type: H 48.50
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Tightening torques for front axle Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tightening torques
Suspension subframe
Axle strut
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Steering gear
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Tightening torques for front axle Page 4 of 7
Steering wiring
Spring strut
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Tightening torques for front axle Page 5 of 7
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Tightening torques for front axle Page 6 of 7
Threaded connection securing line in direction of travel Tightening 15 ftlb. ±1.5 ftlb.
connections to right actuator torque
Threaded connection securing control Tightening 10.5 ±0.5 ftlb.
unit to lines torque ftlb.
Threaded connection securing control Tightening 33 ftlb. ±3.5 ftlb.
unit to accumulator, M14 x 1.5 torque
Pressure sensor to control unit screw Tightening 15 ftlb. ±1.5 ftlb.
connection, M10 x 1 torque
Control unit bracket screw connection Tightening 7.5 ftlb.
torque
Threaded connection securing sensor Replace screws and Tightening 2 ftlb.
to actuator lock nuts after torque
removal.
Bleeder valve screw connection Tightening 5 ftlb.
torque
Drive shaft
Differential
Wheel
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Tightening torques for front axle Page 7 of 7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\3087895_KDNum_0.htm 5/20/2011
Lifting the vehicle Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
DANGER
Risk of injury due to vehicles slipping or tilting off lifting platforms.
Risk of injury due to vehicles slipping or tilting off lifting platforms may be caused by improper
alignment of the lifting platform arms or support plates, and by raising, supporting or removing units
on raised vehicles.
ATTENTION
Danger of material damage if the vehicle is raised incorrectly.
Lifting or supporting the vehicle at unsuitable take-up points can lead to material damage on the
vehicle.
Raising the vehicle in the sill area will lead to the deformation of body parts and to leakage in the
underbody area.
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Lifting the vehicle Page 3 of 5
When driving into the platform lift, pay attention to work to be carried out. i.e. 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.
If the vehicle is a Cayenne with air suspension/level control, observe the following instructions.
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.
Tap the right-hand rocker switch on the center console in the appropriate direction until vehicle has reached
normal level. 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.
To do this:
– Switch on ignition.
The message Control switched off appears in the variable control display of the instrument panel.
To do this:
– Switch on ignition.
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Lifting the vehicle Page 4 of 5
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Lifting the vehicle Page 5 of 5
WARNING
The Offroad Stabilizer System (ORS) operates at an overpressure of
up to 165 bar.
If the ORS is not depressurised, movements may occur on the
wheel carrier under certain circumstances (e.g. the off-road
stabilisers are disengaged when the vehicle is lifted, the switch
on the centre console is pressed and the wheel carrier is also
lifted). The stabilizer can close quickly. Thus there is the danger
of crushing in the area of the stabilizers and wheel carriers.
→ The ORS must be depressurised before working on it. To do this, close the Porsche System Tester and
select in the menu >> Offroad Stabi (ORS) >> Drive links >> clock valve VA or valve HA <<. The valve
clocks (audibly) until the procedure is finished.
→ Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
button must be OFF . If the indicator light is on, follow the following procedure: Switch on the ignition and
engage the road driving programme >> High Range <<. The stabilizers must audibly engage. Now lift the
vehicle.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Tests/notes for all-wheel drive Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Electronic fine balancing (static balancing) of the wheels on the vehicle (after stationary balancing) is not required
(status July 2002).
Power test
Brake test
Brake tests may only be carried out in the road driving programme (High Range) on 1-axle roller-type test stands
with four-wheel drive function. Requirements:
Observe specifications in the operating instructions provided by the relevant manufacturer of the axle roller-type
test stand!
The foot-operated parking brake may only be tested on the roller brake tester with the ignition switched off and
selector lever position N selected.
WARNING
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Tests/notes for all-wheel drive Page 3 of 3
No power assistance for the towed vehicle when the engine is not running.
A lot more force has to be used when braking and steering!
→ Always tow with extreme caution, and at low speeds. Observe the Driver's Manual.
Note
There is insufficient transmission lubrication when the engine is not running.
Select position N.
Switch ignition on (otherwise steering lock will engage and brake light and indicator light won't function).
If, owing to circumstances, vehicle has to be towed with raised axle, the cardan shaft of the axle whose wheels
are turning must be removed.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Overview of Cayenne running gear with steel springs Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Front axle
A wide-base double control arm axle is used for the front axle of the Cayenne, with wheels suspended individually
on double control arms and spring struts with vibration dampers inside.
Steering
Rack-and-pinion steering gear with hydraulic support and - depending on the model - Servotronic for supporting
the steering auxiliary forces when travelling slowly. Steering wheel longitudinally adjustable and with height
adjustment in the corresponding model.
Rear axle
A multi-link axle is used for the rear axle of the Cayenne, with wheels suspended individually on control arms and
vibration dampers inside. The Porsche-specific vehicle handling features of driving comfort and sportiness were
important considerations during development.
The chart of tyres and wheels should be taken from Technical Information Group 4.
Brakes
Hydraulic dual-circuit brake system with diagonal brake circuit division. Vacuum brake booster, internally
ventilated brake discs with six-piston AI monobloc brake calipers at front axle and four-piston AI monobloc brake
calipers at rear axle.
Standard PSM with ABS, ASR (TC+MSR), ABD, lock control (lengthways)
Parking brake (foot-operated parking brake): drum brake acting mechanically on both rear wheels.
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Overview of Cayenne running gear with steel springs Page 3 of 3
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Cayenne system overview Page 2 of 3
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
General
The development team is expected to meet various requirements in developing the Cayenne, e.g. sporty vehicle
handling, tough off-road mission and full suitability for everyday use with maximum driving safety. Through overall
vehicle fine-tuning of the individual systems, such as axles, steering, tyres, aerodynamics and drive design, very
good vehicle handling features were implemented in both on-road and off-road operations with the following
technical specifications:
Single-wheel suspension with steel springs using a large-base double control arm front axle and a multi-link
rear axle (standard for Cayenne S)
Level control system with full-supporting air suspension on both axles and electronically regulated shock
absorbers (standard for Cayenne Turbo, optional for Cayenne and Cayenne S)
Tube-type stabilizers on front and rear axle or hydraulically disengagable off-road stabilizers (optional for all
Cayenne models as part of Porsche Traction Management Plus)
Rack-and-pinion steering gear with hydraulic assistance or speed-dependent Servotronic steering assistance
(optional)
Extensive range of wheels and tyres, high-performance summer tyres, winter tyres, All Season tyres and All
Terrain tyres.
Tyre pressure monitoring system - RDK (optional)
Operating brakes customised to suit driving dynamics
Porsche Stability Management (PSM)
Porsche Traction Management (PTM) or optional Advanced Off-Road technical package with PTM Plus.
System Explanation
PSM (Porsche Stability Management) ABS Anti-lock Brake System
ABD Automatic Brake Differential
ASR Anti-slip control
EBD Electronic Brake Distributor
MSR Engine drag torque control
FDR Driving dynamics control
PTM (Porsche Traction Management) Permanent four-wheel drive 38/62 %
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Cayenne system overview Page 3 of 3
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Safety notes and information when repairing the running gear Page 2 of 5
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
WARNING
Material damage. When mounting specifications are not observed, the long-term behaviour of screw-
connections is nor ensured.
There can be limitations on the service life or function of the components.
→ All parts used on the running gear are subject to a close visual inspection.
→ Only use approved original Porsche parts.
→ Replace self-locking nuts.
→ The prescribed tightening torque must be strictly observed.
→ Observe grease specification (for example, on steering shaft).
→ Ensure that ball joint rod conical seats are clean when fitting. Clean bevel pinions with a lint-free cloth. Do not
use cleaning agent.
ATTENTION
There will be alterations in handling due to installing incorrect parts.
Prior mechanical damage to coil springs due to incorrect handling by the customer or in the workshop
can cause the coil springs to break, even at a later point in time.
→ When installing new coil springs/spring struts, make sure they are assigned correctly according to the Spare
Parts Catalogue.
→ When removing and installing coil springs, only use suitable or specified tools/spring compressors.
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Safety notes and information when repairing the running gear Page 3 of 5
→ No welding, sanding, or separating work in the area of coil springs/spring struts. Cover coil springs/spring
struts.
WARNING
Increased risk of accidents as a result of damage to wheels/tyres if handled improperly.
Injuries due to the high tyre seating pressure required (max. 4 bar! this value must not be exceeded!),
cannot be ruled out.
Welding on light-alloy wheels can cause bulges, which can cause them to break if they are used.
Note
Newly mounted tyres require a bedding-in period to remove the vulcanisation layer.
Customers must be informed that the full performance of new tyres is achieved only after a distance of 100 to
200 km (60 to 120 miles) has been driven. Avoid extreme driving manoeuvres (acceleration, braking) during
this time.
DANGER
Risk of accident due to incorrect functioning of steering angle sensor if it is uncalibrated or incorrectly
calibrated.
There is a risk of accidents causing physical damage to persons or objects in the PSM testing area.
→ After working on wheel suspension parts, when replacing the steering-angle sensor, and after changing the
wheel alignment values, calibrate the steering angle sensor with the front wheels in straight-ahead position
using the PIWIS tester.
→ Check the actual value of the steering angle sensor after a suspension alignment where no changes were
made to the wheel alignment values.
Brake system
WARNING
Increased risk of accidents and damage to the vehicle if braking effect is impaired by using non type-
specific original Porsche spare parts, if the brake pads and/or brake discs are replaced too late.
There can be limitations on the service life or function of the components.
→
Use only the type-specific brake pads (correct brake pad quality) in the Porsche Spare Parts Catalogue.
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Safety notes and information when repairing the running gear Page 4 of 5
When installing a new expanding spring, mount a new retaining pin and new retainer (safety bracket) or
retaining pin screw on the brake calliper.
→ After repairs to the brake system, the brake pressure must be built up again by applying the brake pedal
several times.
→ The brake pads must be replaced when the brake pad warning indicator lights up, but no later than when
there is a residual pad thickness of 2 mm.
→ Replace brake discs in good time (observe minimum brake disc thickness and surface condition).
Note
Observe brake fluid quality. Use only new DOT 4 brake fluid.
The brake-fluid change interval using Super DOT4 brake fluid is two years.
This brake fluid is available under the following part numbers: Container quantity: 1 litre = 000.043.203.66. 30
litres = 000.043.203.67.
WARNING
A triggering of the airbag (malfunction in the airbag system) caused by improper work on airbag
components cannot be ruled out.
In the case of malfunction, an unsuitable steering wheel holder can cause injury or damage during
suspension alignment work.
→ Use only steering wheel holders which do not project into the area of the airbag unit during suspension
alignment work.
→ Observe safety regulations for airbag vehicles.
Steering
WARNING
Risk of accidents accompanied by danger of injury and damage to the vehicle due to incorrect handling of
Pentosin CHF 11 S.
It is possible that the reservoir can overflow while driving if too much Pentosin CHF 11 S is added.
Overflowing onto hot components can cause fires.
If coolant hoses come into contact with Pentosin CHF 11 S for a longer period of time, they will swell.
Note
Rack-and-pinion steering gear and servo pump must not be repaired or dismantled.
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Safety notes and information when repairing the running gear Page 5 of 5
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing front-axle carrier Page 2 of 12
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing front-axle carrier Page 3 of 12
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Preliminary work
Preliminary work
In vehicles with level adjustment: Switch off level adjustment. → Lifting the vehicle
Raise the vehicle at the support points provided for this purpose. → Lifting the vehicle
Tools
Tools
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Removing and installing front-axle carrier Page 5 of 12
ATTENTION
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Note
These removal and installation instructions apply to vehicles with level adjustment and steel springs. The
points relating to level adjustment are not relevant for vehicles with steel springs.
1. Open the engine compartment lid and secure with the bonnet stay 97040.
Note
Point 3 is not necessary for a 6-cylinder engine. There is a perforated
plate at both the front right and rear left of the engine for transporting
and raising to the safety device.
4. Position the safety device 10-222 A correctly and fit the chain to the
fastening bracket -A- . Fit the transport eyebolt 97000 for securing
the engine -B- (the bore for the transport eyebolt is located between
cylinder 6 and 7 on the left cylinder bank).
5. Remove the front wheels. → 440519 Removing and installing wheel - section on "Removing"
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6. Remove engine guard. → 108019 Removing and installing engine guard - section on "Removing"
Note
The spring struts are not removed in order to remove the front axle
carrier.
Fix upper axle strut. The lower control arms are loosened on the front
axle carrier and remain with the spring struts in the vehicle.
7. Fix upper axle struts with spring compressor VW 552. This involves
tensioning the axle strut slightly because otherwise the top ball joint
can be damaged. When doing this, engage the -connecting piece-
into the top opening of the wheel well (double panel, under the wheel
housing cover) and into the axle strut (do not disconnect the air spring
connection!).
8. For easier removal of the outer tie rod end, swivel the relevant wheel
carrier so that the tie rod extends fully. Remove the
-outer tie-rod joints- using press-out tool T10187. When pressing
out, screw fastening nut on flush (protects the ball joint thread).
9. The screw in the steering shaft is removed from the wheel well.
Release the coolant hoses from the holders on the body. Release the
-steering column screw (arrow)- from the steering gear.
10. Remove the hydraulic lines from the steering gear (collect hydraulic
fluid in a suitable container). Remove the heat shield of the steering, if
necessary.
11. Mark the installation position of the cardan shaft and remove it from
the front-axle final drive. Make sure that the cardan shaft does not
become kinked (tie it up). → 390219 Removing and installing front
cardan shaft - section on "Removing" [9PAAE1 9PAAF1]→ 390219
Removing and installing front cardan shaft - section on "Removing"
[9PAAE7]
12. Remove drive shafts from the front-axle final drive. Make sure that the drive shafts do not become kinked (tie
them up).
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13. Remove lower control arms from the front axle carrier.
Note
The mounting points for the front axle carrier (1 and 3), both right and
left, and the two positioning guides (4) that are pushed into the body
are required for removing the front axle carrier. The other mounting
points can be removed.
The mounting points 1/11 (designation on the guide pin) are fitted into
-Position 1- . Double codes (e.g. 11, 22) are also used for mounting
the rear axle.
Mounting frame
A second worker is required in order to avoid damaging adjacent components when lowering the front axle
carrier.
For installation, it is a good idea to mark the installation position of the front axle carrier diagonally at at least
two places on the body. To do this, place the marks vertically with respect to the floor of the body using a felt-
tip pen (e.g. mark along the front-axle carrier mount with the pen).
15. Position the -workshop trolley- with the correctly positioned mounting frame under the front axle carrier.
16. Mark the installation position of the front axle carrier diagonally at at least two places on the body.
17. The -arrow- show the mounting points for the mounting frame in the front axle carrier (view from below here).
18. Position the front axle carrier into the mounting points provided -(arrows)- (points 4 in the body).
19. Remove the 4 fastening screws -(arrows)- of the front axle carrier.
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20. Lower the front axle carrier with steering, final drive and stabiliser. Be careful not to damage adjacent parts
(e.g. cardan shaft, oil pan, body).
21. Remove accessories from the front axle carrier (steering, final drive, stabiliser). Get another worker to help.
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ATTENTION
Increased risk of accidents when running in the front axle carrier.
Material damage and injury can occur.
Material damage and injury if the wheel carrier is raised improperly.
→ Position the mounting frame correctly on the lifting platform and carefully install the front axle carrier.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When
raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
→ Watch out for falling parts during installation on the mounting frame.
→ The steering angle sensor must be calibrated following repairs.
Note
Before installing, give the parts a visual check.
Note previously applied markings on the front axle carrier and on the cardan shaft.
A second worker is required in order to avoid damaging adjacent components when fitting the front axle
carrier.
When fitting the ball joints, ensure that the bevel pinions are clean! Remove dirt or grease on bevel pinions,
e.g. with a lint-free cloth. Do not use cleaning agent/solvent.
Replace all fastening nuts and all expansion screws (screws which are fitted with torque angle tightening
procedure).
Do not raise the wheel suspension higher than the normal vehicle
position (vehicle resting on wheels). When raising the suspension, use
a suitable -intermediate layer (hard rubber)- . Do not damage the
brake cover plate.
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2. Pre-fit the accessories on the front axle carrier (steering, final drive, anti-roll bar). Get another worker to help.
3. Position the front axle carrier back in the original, marked installation position and be careful not to damage
adjacent parts.
5. Remove the -workshop trolley- with the mounting frame and secure
the water hose holders.
6. Fit the steering gear to the steering column and connect the hydraulic
lines.
7. Fit the cardan shaft at the points marked.→ 390219 Removing and
installing front cardan shaft - section on "Installing" [9PAAE1 9PAAF1]
→ 390219 Removing and installing front cardan shaft - section on
"Installing" [9PAAE7]
9. Fit the tie rod ends. The tightening torque for the fastening nut for Front axle carrier
attaching the tie rod end is 70 Nm (52 ftlb.).
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10. Fit the engine guard → 108019 Removing and installing the engine guard - section on "Installing" and the
front wheels → 440519 Removing and installing wheel - section on "Installing".
11. Remove the safety device 10-222 A. To do this, remove the transport eyebolt 97000 -B- and the chain -A- ,
which is used to secure the engine.
Subsequent work
Subsequent work
Align the vehicle → Suspension alignment, complete and calibrate it → Initialising and calibrating steering-angle
sensor.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Replacing bearings for carrier Page 2 of 9
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
Preliminary work
1. Switch off level adjustment. → 40 Lifting the vehicle
On vehicles with ORS, depressurise the system using the PIWIS Tester.
Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
button must be OFF. If the indicator light is on, follow the following procedure: Switch on the ignition and
engage the road driving programme >> High Range <<. The anti-roll bars must engage audibly.
Before working on the ORS, always depressurise the system! To do this, close the PIWIS Tester and select
>> Offroad Stabi (ORS) >> Drive links >> Clock FA valve or RA valve <<. The valve clocks (audibly) until the
procedure is finished (approx. 20 seconds).
WARNING
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Risk of accidents! The Offroad Stabilizer System (ORS) operates at an overpressure of up to 165 bar.
Under certain conditions, motions can occur on the wheel carrier (e.g. if the Offroad stabilizers are
disengaged when lifting, the button is pressed on the centre console, and the wheel carrier is also
raised). The stabilizer can close quickly.
Danger of crushing in the area of the stabilizers and wheel carriers. Risk of injury and material
damage due to raising the wheel carrier incorrectly.
→ Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
button must be OFF. If the indicator light is on, follow the following procedure: Switch on the ignition and
engage the road driving programme >> High Range <<. The anti-roll bars must engage audibly.
→ Before working on the ORS, always depressurise the system! To do this, close the PIWIS Tester and select
>> Offroad Stabi (ORS) >> Drive links >> Clock FA valve or RA valve <<. The valve clocks (audibly) until the
procedure is finished (approx. 20 seconds).
ATTENTION
Danger of injury due to falling tools.
Danger of crushing and deformation
Tools
-A- - → Hydraulic cylinder VAS 6178 (The hydraulic cylinder is used together with the → foot pump VAS 6179
and the → pressure gauge with connecting cable VAS 6179/1 -B- .)
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-1- - Threaded rod (Inserted into the tubular piston cylinder -A- .)
-2- - Threaded nut (Screwed onto the threaded rod -1- .)
-3- - Pipe (For pressing out the suspension subframe bearings.)
-4- - Ring (For pressing out the suspension subframe bearings.)
-5- - Press-out plate (For pressing out the suspension subframe bearings.)
. -6- - Pressure piece (For pressing in the suspension subframe bearings.)
-7- - Press-in plate (For pressing in the suspension subframe bearings.)
-8- - Ring (For pressing out the suspension subframe bearings.)
-9- - Spacer sleeve (For pressing out the suspension subframe bearings together with pipe -3- .)
-10- - Pressure piece (For pressing in the suspension subframe bearings.)
-11- - Spacer sleeve (For pressing in the suspension subframe bearings.)
Replacing
Note
If a suspension subframe bearing is replaced, the other bearings must also be checked for cracks or other signs
of damage.
1. Loosen the anti-roll bar from the connecting link on both sides. (Do not loosen the anti-roll bar for the rear
front-axle bearings!)
2. Move the gear support under the engine transverse bar and lift it
slightly using a suitable base (e.g. hard rubber support). (The gear
support is not needed for the rear front-axle bearings).
4. Loosen the suspension subframe bearing on both sides, carefully lower the gear support (loosen the spindle
carefully at the same time) until you get the clearance needed for using the press-out tool.
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Note
Hold the hydraulic cylinder VAS 6178 tightly while pressing it out.
6. Attach the tools as shown in the illustration and press out the
bearing.
Note
When replacing bearings, please make sure that one arrow is pointing in
the direction of travel while the other arrow is pointing away from the
direction of travel.
8. Press in suspension subframe bearing. To avoid damaging the bearing, the maximum → Pressure: 10 kN
+/-5 Sekunde must not be exceeded at the stop (10 KN = 350 bar). This conversion applies only to the
hydraulic cylinder VAS 6178. The conversion depends on the diameter of the cylinder in question.
9. Attach the tools as shown in the illustration and press in the bearing.
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Note
Observe correct tightening torques.
10. Carefully lift the suspension subframe until the installation position is
reached. Fit threaded joint on suspension subframe bearing.
Note
If a suspension subframe bearing is replaced, the other bearings must also be checked for cracks or other signs
of damage.
1. Engage the spindle at the eyelet on the engine transverse bar at the side where you want to replace the
bearing. Guide the spindle through the lower trailing arm and tighten the spindle slightly so that the spindle is
slightly tensioned.
2. Loosen the suspension subframe bearings on both sides. Loosen the spindle carefully until there is sufficient
clearance for using the press-out tool.
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Replacing bearings for carrier Page 8 of 9
Pressing out front-axle bearing at the Tools for pressing out front-axle
rear bearings at the rear
4. Attach the tools as shown in the illustration and press out the bearing.
Note
When replacing bearings, please make sure that one arrow is pointing in
the direction of travel while the other arrow is pointing away from the
direction of travel.
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Note
Observe correct tightening torques.
Subsequent work
Subsequent work
1. Fit underbody protection. → 50 Underbody protection
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing top axle strut - Steel spring Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing top axle strut - Steel spring Page 3 of 6
Preliminary work
Preliminary work
Remove the wheel. → 440519 Removing and installing wheel - chapter on "Removing"
Tools
-A- - press-out tool T10187 - to press out the ball joint on the wheel carrier.
-B- - spring compressor VW 552 - for slightly tensioning the upper trailing arm.
ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
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Removing and installing top axle strut - Steel spring Page 4 of 6
2. Fix upper axle strut with spring compressor VW 552. This involves
tensioning axle strut slightly because top ball joint can otherwise get
damaged. When doing this, the -Spring compressor- is pushed
through the hole in the axle strut, engaged in the upper opening of
the wheel well (double panel) and in the axle strut and tightened with
the nut. This is only necessary if the same control arm is reinstalled.
4. Release fastening nut and press ball joint rod off with the press-out
tool T10187.
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ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
Note
The entire threaded parts of the axle must be tightened in vehicle
position. Vehicle position means: vehicle standing on the wheels, or
the wheel suspension is being raised with a universal vehicle lift.
-Dimension X- , from → Control value: 502 mm +/-10 mm
corresponds to the vehicle position.
Grease the toothing of the drive shaft slightly with aluminium paste
Optimoly TA.
Do not leave drive shafts hanging from the joint stop. Support wheel
carriers.
Make sure the bevel pinions from the ball joints are clean. Clean with a lint-free cloth as necessary. Do not
use cleaning agent.
2. Insert upper trailing arm and fastening bolts. Fit lock nuts and tighten to specified tightening torque. →
Tightening torques for front axle
3. Install spring strut → 408519 Removing and installing front spring strut (steel springs) - chapter on
"Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7]→ 408519 23 Removing and installing front spring strut
(steel springs) - chapter on "Installing" [9PAAF1 9PAAJ1].
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4. Insert wheel carrier in the ball joint, fit lock nuts, and tighten to specified tightening torque. → Tightening
torques for front axle
Subsequent work
Fit the wheel → 440519 Removing and installing wheel - chapter on "Installing" and tighten to specified tightening
torque. → Tightening torques for front axle
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing bottom axle strut Page 2 of 7
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing bottom axle strut Page 3 of 7
Preliminary work
Preliminary work
Remove the wheel. → 440519 Removing and installing wheel - chapter on "Removing"
Tools
-A- - press-out tool T10187 - to press out the ball joint on the wheel carrier.
-B- - spring compressor VW 552 - for slightly tensioning the upper trailing arm.
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ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle
position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard
rubber) .
→ Do not damage the brake cover plate.
2. Fix upper axle strut -Inset 1- with spring compressor VW 552. This
involves tensioning axle strut slightly because top ball joint can
otherwise get damaged. When doing this, the -Spring compressor-
is pushed through the hole in the axle strut, engaged in the upper
opening of the wheel well (double panel) and in the axle strut and
tightened with the nut.
3. Loosen the fastening nuts → see figure from the bottom ball joint and press off with the press-out tool
T10187. When doing this, leave fastening nut flush on ball journal, so as not to damage thread.
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4. Remove the lower fastening screw of the spring strut -arrow- . For this purpose, lift wheel carrier with a
suitable lift -Lift with a rubber base- (to prevent slipping) to the extent that the screw -arrow- can be
unscrewed easily.
6. Then remove eccentric screws. When doing so, ensure that joint boot
is not damaged by eccentric -arrow- . Pull (press) axle strut out of
the subframe mounting points -A- .
7. Remove fastening nut -Inset 5- from ball joint. Tilt -trailing arm- down all the way and pull ball joint carefully
out of the wheel carrier.
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ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
Note
The entire threaded parts of the axle must be tightened in vehicle position. Vehicle position means: vehicle
standing on the wheels, or the wheel suspension is being raised with a universal vehicle lift. -Dimension X- ,
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Removing and installing bottom axle strut Page 7 of 7
Use an intermediate layer (hard rubber). Do not damage the brake cover plate.
Subsequent work
Following this repair work, the vehicle suspension must be aligned. → Suspension alignment, complete
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Replacing bearing for trailing arm Page 2 of 13
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
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1. Raise the vehicle → 40 Lifting the vehicle and remove wheel → 440519 Removing and installing wheel -
section on "Removing".
2. Remove lower trailing arm → 401719 Removing and installing lower trailing arm.
ATTENTION
Increased risk of accidents when working with hydraulic presses - danger of crushing, deformation of
components.
Risk of injury if the threaded rod in the tubular piston cylinder breaks because of pressure or
traction.
Possible danger of damage or injury.
→ The worker must always stand away from the direction of pressure or traction on the threaded rod when
using the tubular piston cylinder.
→ Position pressure pieces correctly and ensure that they are seated properly.
→ Watch out for falling parts when working with hydraulic presses.
→ Danger of injury and material damage if the wheel carrier is raised incorrectly.
→ Do not damage the brake cover plate.
ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
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Chapter 2.2.3"
-2- Nut with collar - assembly fixture T10230 → "See Screwed onto the
Workshop threaded rod -1- .
Equipment
Manual,
Chapter 2.2.3 "
-4- Pressure piece 40 - assembly fixture T10230 → "See For pressing out the
Workshop bearing -C- .
Equipment
Manual,
Chapter 2.2.3 "
-5- Pipe 56 - assembly fixture T10230 → "See For pressing out the
Workshop bearing -B, C- .
Equipment
Manual,
Chapter 2.2.3 "
-7- Adjusting washer - assembly fixture T10230 → "See Screwed into the
Workshop tubular piston
Equipment cylinder VAS 6178
Manual, -A- with two
Chapter 2.2.3 " countersunk screws.
For pressing out
bearing -A, B, C- .
For pressing in
bearing -C- .
-8- Support - assembly fixture T10230 → "See For pressing in the
Workshop bearing -C- .
Equipment
Manual,
Chapter 2.2.3 "
-9- Pipe 72 - assembly fixture T10230 → "See For pressing out the
Workshop bearing -A- .
Equipment
Manual,
Chapter 2.2.3 "
-10- Pressure piece 60 - assembly fixture T10230 → "See For pressing in the
Workshop bearing -B- .
Equipment
Manual,
Chapter 2.2.3 "
-11- Support - assembly fixture T10230 → "See For pressing in the
Workshop bearing -A- .
Equipment
Manual,
Chapter 2.2.3 "
-12- Ring - assembly fixture T10230 → "See Screwed into the
Workshop tubular piston
Equipment cylinder VAS 6178
Manual, -A- with two
Chapter 2.2.3 " countersunk screws.
For pressing in the
bearing -A, B- .
-13- Pressure piece 45 - assembly fixture T10230 → "See For pressing out the
Workshop bearing -B- .
Equipment
Manual,
Chapter 2.2.3 "
-T10205/13- Pressure head - attachments T10205 Pressure head from
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assembly fixture
T10205 (!); screwed
into the tubular
piston cylinder VAS
6178 -A- .
-14- Washer - assembly fixture T10230 Placed on the
threaded rod -1- .
-15- Nut - assembly fixture T10230 Commercially
available M14 nut.
Screwed onto the
threaded rod -1- .
Replacing
Note
The pressure pieces and the tubular piston cylinder VAS 6178 are used
for removal. This involves screwing pressure head T10205/13 into the
tubular piston cylinder. T10230/2 is screwed on to the threaded rod and
positioned in T10205/13 for pressing bearings in and out. Nut T10230/15
and washer T10230/14 are screwed onto the opposite end of the threaded
rod .
The following pressure pieces and nuts are required for bearings -A- :
T10230/2
T 10230/7
T10230/9
T10230/10
T10230/14
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T10230/15
Note
When using the pressure pieces, the direction arrow shows the direction
for pressing the rubber-metal mounts in or out on the trailing arm.
T10230/2
T10230/11
T10230/12
T10230/14
T10230/15
Note
When using the pressure pieces, the direction arrow shows the direction for pressing the rubber-metal mounts in
or out on the trailing arm.
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Note
When pressing the mounts in, make sure that pressure piece 11, in
particular, is positioned correctly. Pressure piece 11 must not cover up the
bore for the bearing in the control arm!
The following pressure pieces and nuts are required for bearings -B- :
T10230/2
T10230/5
T10230/7
T10230/13
T10230/14
T10230/15
Note
When using the pressure pieces, the direction arrow shows the direction for pressing the rubber-metal mounts in
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T10230/2
T10230/10
T10230/12
T10230/14
T10230/15
Note
When using the pressure pieces, the direction arrow shows the direction for pressing the rubber-metal mounts in
or out on the trailing arm.
The pressure pieces are used as follows → Arrangement of tools for pressing in spring-strut mounts .
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The following pressure pieces and nuts are required for bearings -C- :
T10230/2
T10230/4
T10230/5
T10230/7
T10230/14
T10230/15
Note
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When using the pressure pieces, the direction arrow shows the direction
for pressing the rubber-metal mounts in or out on the trailing arm.
T10230/2
T10230/7
T10230/8
T10230/14
T10230/15
Note
When using the pressure pieces, the direction arrow shows the direction for pressing the rubber-metal mounts in
or out on the trailing arm.
The pressure pieces are used as follows → Arrangement of tools for pressing in rubber-metal mounts .
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Subsequent work
Subsequent work
Note
The entire threaded joints of the axle must be tightened in vehicle position. Vehicle position means: vehicle
standing on the wheels, or the wheel suspension is raised with a universal vehicle lift. Dimension -X- , from
→ Control value: 502 mm +/-10 mm corresponds to vehicle position.
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Replace all expansion screws (screws which are fitted with torque
angle tightening procedure).
Make sure the bevel pinions from the ball joints are clean. Clean with
a lint-free cloth as necessary. Do not use cleaning agent.
1. Install lower trailing arm → 401719 Removing and installing lower trailing arm.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing control unit for off-road stabilizer Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
The control unit for the Offroad stabilizer is located in the luggage compartment under the loadspace floor
beside the collapsible spare wheel.
Installation Location:
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2. Insert plug -2- into the control unit until it clicks into place.
3. Insert plug -1- into the control unit until it clicks into place.
Note
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If a new control unit has been installed for the Offroad stabilizer,
continue with → 402419 Removing and installing control unit for
Offroad stabilizer - "Coding" section.
Note
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.
If faults are present in the fault memory, which cannot be deleted or if the faults are displayed repeatedly, proceed
according to Rep.-Gr. 4024 Diagnosis Manual - ORS.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
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WARNING
The Offroad Stabilizer System (ORS) operates at an overpressure of up to 165 bar. If the ORS is not
depressurised, movements may occur on the wheel carrier under certain circumstances (e.g. the off-road
stabilisers are disengaged when the vehicle is lifted, the switch on the centre console is pressed and the
wheel carrier is also lifted).
The stabilizer can close quickly. Thus there is the danger of crushing in the area of the stabilizers
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and wheel carriers. Danger of injury and material damage if the wheel carrier is raised incorrectly.
→ Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
button must be OFF . If the indicator light is on, follow the following procedure: Switch on the ignition and
engage the road driving programme >> High Range <<. The stabilizers must audibly engage.
→ Before working on the ORS, depressurise the system. To do this, close the Porsche System Tester and
select in the menu >> Offroad Stabi (ORS) >> Drive links >> clock valve VA or valve HA <<. The valve
clocks (audibly) until the procedure is finished.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When
raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
1. Connect the Porsche System Tester and depressurise the system. To do this, select the menu items >> Off-
road Stabiliser (ORS) >> Drive links >> Set front-axle or rear-axle valve <<. The valve clocks (audibly) until
the procedure is finished.
2. Open the luggage-compartment lid and remove the rear left side-panel lining → 700319 Removing and
installing rear luggage compartment side-panel lining - section on "Removing".
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7. Pull the oil dipstick along with the filler tube and vent tube -arrow- out
of the expansion tank. Press the relevant plastic ring on the fluid tank
down evenly using the removal tool, universal NR.21.
8. The hydraulic lines are fed out through the luggage compartment
floor panel. Loosen the lines from outside and ensure when removing
the lines that the seals are not lost when passed through the body. If
fluid emerges, place a lint-free cloth, for example, underneath. Clean
the luggage compartment floor panel IMMEDIATELY if necessary.
9. Disconnect electric plugs.
10. Remove the three fastening screws on the control unit -arrows- and
take out the control unit.
Note
Bleed the off-road stabiliser system (ORS).
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2. Guide the hydraulic lines of the control unit carefully through the body and secure into position. Fit seals.
3. Fit the control unit into the take-up points provided -arrows- .
4. Insert filler neck with filler tube and vent tube and slide in as far as
the wide section -arrow- . Insert oil dipstick.
To ensure that there are no leaks in the system, fill and bleed the off-road
stabiliser system (ORS) before installing the four-zone air-conditioning
system. Then perform a visual check for leaks on the control unit
(expansion tank, sensor connections, etc.).
6. The off-road stabiliser system is filled with Pentosin CHF 11S using
the dipstick opening → see figure → 407707 Bleeding the Off-Road
Stabiliser System (ORS).
7. Bleed the off-road stabiliser system (ORS). → 407707 07 Bleeding the Off-Road Stabiliser System (ORS) -
section on "Bleeding". The fluid level can be checked by reading the marking on the dipstick → see figure .
8. Do not top up above the max. marking → see figure . Fit the cover of the oil dipstick.
9. Insert and fit the four-zone air-conditioning system -arrow- → 881019 Removing and installing auxiliary air-
conditioning unit - section on "Installing".
Subsequent work
Subsequent work
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
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Off-Road Stabiliser System (ORS) - Checking fluid level Page 3 of 5
Note
Before the fluid level is checked, the Offroad stabilizer must be >> disengaged and engaged << four times.
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2. Activate the Offroad stabilizer button four times. The indicator light
-arrow- comes on. Only initiate the next switching operation when
the off-road stabilizer has >> disengaged or engaged << audibly.
3. Switch off the off-road driving program >> Low Range << again.
2. The solenoid valve clocks (audibly) until the overpressure has been
equalized. The fluid level in the reservoir of control unit C of the
Offroad stabilizer rises.
3. The valve no longer clocks. Now the correct fluid level can be read
on the dipstick.
4. Reading and correcting the fluid level is described in the next chapter.
5. Unplug Porsche System Tester. After switching on the ignition again and engaging Low Range, the system
adjusts automatically to the correct pressure.
The reservoir is not freely accessible. It is filled using the dipstick opening. To do this, refill the amount of fluid
necessary using suitable filling equipment. Pull out the dipstick several times and check the fluid level.
1. The dipstick is accessible below the upper cover -arrow- , rear left, in the centre of the D-pillar. Remove the
cover.
2. The dipstick -arrow- inserted in the left D-pillar. Pull out the dipstick.
3. The fluid level must be between the markings on the dipstick . Do not top up above the → see figure Max.
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mark.
4. The off-road stabiliser system is filled with Pentosin CHF 11S using
the → see figure dipstick opening .
5. After the work is completed, insert the dipstick and fit the cover.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Bleeding the Off-Road Stabiliser System (ORS) Page 2 of 6
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
WARNING
The Off-road Stabilizer System (ORS) operates at an overpressure of up to 165 bar. Under certain
conditions, motions can occur on the wheel carrier (e.g., if the Off-road stabilizers are disengaged when
lifting, the button is pressed on the centre console, and the wheel carrier is also raised).
The stabilizer can close quickly. Thus there is the danger of crushing in the area of the stabilizers
and wheel carriers.
→ Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
button must be OFF . If the indicator light is on, follow the following procedure: Switch on the ignition and
engage the road driving programme >> High Range <<. The stabilizers must audibly engage.
→ Before working on the ORS, depressurise the system. To do this, close the Porsche System Tester and
select in the menu >> Offroad Stabi (ORS) >> Drive links >> clock valve VA or valve HA
<<. The valve clocks (audibly) until the procedure is finished.
→ Wear protective gloves and goggles.
Note
The driving programs can be selected using the rocker switch on centre console. The -arrow- on the
indicator light displays if the road driving programme >> High Range << (light OFF) or the offroad
program >> Low Range << (light ON) is engaged.
1. Connect the bleeder valves of the actuator to the front axle with a suitable transparent hose and open
approx. one turn.
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2. Connect the bleeder valves of the actuator to the rear axle with a suitable transparent hose and open
approx. one turn.
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3. To prevent the hoses from slipping from the bleeder valves, they
must be fastened using screw-type hose clamps/tie wraps. Because
of the high pressure occurring, they can become loose during the
bleeding process.
4. Fill with Pentosin CHF 11S in the opening of the dipstick -arrow- .
The opening is located at the left rear, in the centre of the D-pillar.
5. Pull out the dipstick and fill with Pentosin CHF 11S using suitable filling equipment.
6. Fill with Pentosin CHF 11S up to the Max. marking of the dipstick.
Note
Connect the Porsche System Tester and switch on the hydraulic pump in the menu >> Offroad Stabi
(ORS) >> Drive links >> Switch on electrical hydraulic pump <<.
Only allow the hydraulic pump to run for max. 10 seconds when switching it on for the first time following
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repairs.
Switch on the hydraulic pump the 3rd time. The Pentosin CHF 11S is pumped through the lines. Perform a visual
inspection of the front and rear axle for lack of air bubbles.
Let the hydraulic pump run until air bubbles can no longer be seen on the hoses of the actuators. Let the hydraulic
pump run for approximately an additional 1 minute. Only then it is ensured that the return line is also completely
rinsed out.
Switch off the hydraulic pump. Check the fluid levels on the oil dipstick and if necessary, top up to the Max.
marking.
Disconnect the Porsche System Tester, switch off the ignition, and close the bleeder valves of the actuators.
Remove the hoses. To protect the bleeder valves, attach the protective caps.
Checking operation
Checking operation
Note
After pressing the button on the centre console, the hydraulic pump
starts (audibly). The stabilizers disengage or engage when a specific
overpressure has been reached in the system. A time delay between
activation until disengaging/engaging (audible) is normal.
Switch on the ignition, press the brake pedal, and engage Low Range. To
do this, briefly press the rocker switch -direction arrow- forwards. The
indicator light -arrow- comes on.
The stabilizers disengage. In other words: Press the button on the centre console. The button light -arrow- comes
on.
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Press the button again. The button light -arrow- goes out. The stabilizers
engage again audibly and the indicator light in the instrument cluster goes
off.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Raise vehicle → 40 Lifting the vehicle.
WARNING
The Off-road Stabilizer System (ORS) operates at an overpressure of up to 165 bar. Under certain
conditions, motions can occur on the wheel carrier (e.g., if the Off-road stabilizers are disengaged when
lifting, the button is pressed on the centre console, and the wheel carrier is also raised).
The stabilizer can close quickly. Thus there is the danger of crushing in the area of the stabilizers
and wheel carriers.
→ Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
button must be OFF . If the indicator light is on, follow the following procedure: Switch on the ignition and
engage the road driving programme >> High Range <<. The stabilizers must audibly engage.
→ Before working on the ORS, depressurise the system. To do this, close the Porsche System Tester and
select in the menu >> Offroad Stabi (ORS) >> Drive links >> clock valve VA or valve HA
<<. The valve clocks (audibly) until the procedure is finished.
→ Wear protective gloves and goggles.
Note
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1. Connect the bleeder valves of the actuator to the front axle with a
suitable transparent hose and open approx. one turn.
2. Connect the bleeder valves of the actuator to the rear axle with a suitable transparent hose and open
approx. one turn.
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3. To prevent the hoses from slipping from the bleeder valves, they
must be fastened using screw-type hose clamps/tie wraps. Because
of the high pressure occurring, they can become loose during the
bleeding process.
4. Fill with Pentosin CHF 11S in the opening of the dipstick -arrow- .
The opening is located at the left rear, in the centre of the D-pillar.
5. Pull out the dipstick and fill with Pentosin CHF 11S using suitable
filling equipment.
6. Fill with Pentosin CHF 11S up to the Max. marking of the dipstick.
Note
Connect the Porsche System Tester and switch on the hydraulic pump in the menu >> Offroad Stabi
(ORS) >> Drive links >> Switch on electrical hydraulic pump <<.
Only allow the hydraulic pump to run for max. 10 seconds when switching it on for the first time following
repairs.
Switch on the ignition, press the brake pedal, and engage High Range. Connect the Porsche System Tester and
switch on the hydraulic pump for 10 seconds. The Pentosin CHF 11S is pumped through the lines.
Switch off the hydraulic pump. Check the fluid levels on the oil dipstick and top up to the Max. marking.
Switch on the hydraulic pump the 2nd time for 10 seconds. The Pentosin CHF 11S is pumped through the lines.
Switch off the hydraulic pump. Check the fluid levels on the oil dipstick and top up to the Max. marking.
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Switch on the hydraulic pump the 3rd time. The Pentosin CHF 11S is
pumped through the lines. Perform a visual inspection of the front and rear
axle for lack of air bubbles.
Let the hydraulic pump run until air bubbles can no longer be seen on the
hoses of the actuators. Let the hydraulic pump run for approximately an
additional 1 minute. Only then it is ensured that the return line is also
completely rinsed out.
Switch off the hydraulic pump. Check the fluid levels on the oil dipstick and
if necessary, top up to the Max. marking.
Disconnect the Porsche System Tester, switch off the ignition, and close
the bleeder valves of the actuators. Remove the hoses. To protect the
bleeder valves, attach the protective caps.
Checking operation
Note
After pressing the button on the centre console, the hydraulic pump
starts (audibly). The stabilizers disengage or engage when a specific
overpressure has been reached in the system. A time delay between
activation until disengaging/engaging (audible) is normal.
Switch on the ignition, press the brake pedal, and engage Low Range. To
do this, briefly press the rocker switch -direction arrow- forwards. The
indicator light -arrow- comes on.
The stabilizers disengage. In other words: Press the button on the centre
console. The button light -arrow- comes on.
Press the button again. The button light -arrow- goes out. The stabilizers engage again audibly and the indicator
light in the instrument cluster goes off.
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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing front drive shaft Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing front drive shaft Page 3 of 8
Preliminary work
Preliminary work
1. Release fastening nut for drive shaft.
Tools
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ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle
position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard
rubber) .
→ Do not damage the brake cover plate.
1. Push (press in) peg into the wheel hub with universal drive shaft/wheel hub extractor as of model '86
NR.87-1. → Insertion length: 20 mm +5 mm
3. Fix -upper trailing arm- with spring compressor VW 552 (vehicle in illustration with conventional
suspension). This involves tensioning axle strut slightly because top ball joint can otherwise get damaged.
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When doing this, the -spring compressor- is pushed through the hole in the axle strut, engaged in the
upper opening of the wheel well (double panel) and in the axle strut and tightened with the nut. This is only
necessary if the same control arm is reinstalled.
4. Press out tie rod on wheel carrier with press-out tool T10187.
→ see figure When pressing out, screw fastening nut on flush
(protects the ball joint thread).
5. Release lower spring strut.
7. Raise wheel carrier with a suitable lift to the extent that connecting rod and fastening pins for spring strut at
the bottom are easy to remove. Use a -lift with a rubber base- to prevent slipping.
9. Unclip cable for wear monitor and release holder on wheel carrier.
10. Disconnect the cable on the ABS sensor.
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11. Press out wheel carrier at the top with press-out tool T10187. → see figure
12. Push the protection over the drive shaft and release the drive shaft at the transmission.
13. 1. One worker must carefully pull upper wheel carrier out and turn the steering. 2. The second worker must
carefully pull out drive shaft.
ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
Note
The entire threaded parts of the axle must be tightened in vehicle position. Vehicle position means: vehicle
standing on the wheels, or the wheel suspension is being raised with a universal vehicle lift. -Dimension X- ,
from → Control value: 502 mm +/-10 mm corresponds to the vehicle position.
Use an intermediate layer (hard rubber) ! Do not damage the brake cover plate.
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Make sure the bevel pinions from the ball joints are clean. Clean with a lint-free cloth as necessary. Do not
use cleaning agent.
1. Grease toothing with a little Optimoly TA aluminium paste and insert drive shaft. When doing this, press
inner joint together tightly.
2. Grease the mounting-face ring of the axle nut with a little Optimoly
TA aluminium paste. Screw on the axle nuts in order to prevent the
shaft from slipping out.
Note
If it is not possible to push shaft in all the way, use press-out tool
T10187 to pull drive shaft in.
3. Insert upper wheel carrier and tie rod, mount using fastening nuts,
then tighten to the specified torque. → Tightening torques for front
axle Pay attention to inner joint of drive shaft.
4. Raise wheel carrier with a suitable lift to the extent that connecting rod and fastening pins for spring strut at
the bottom are easy to push in.
6. Engage cable for wear monitor and mount holder on wheel carrier.
Subsequent work
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Subsequent work
1. Mount the drive shaft on the transmission and tighten to the specified tightening torque. → Tightening
torques for front axle
2. Tighten lock nut for the drive shaft to the specified tightening torque. → Tightening torques for the front
axleOperate the brake whilst doing so (second fitter required).
3. Fit the wheel → 440519 Removing and installing wheel - section on "Installing" and tighten to the specified
tightening torque. → Tightening torques for front axle
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Disassembling and assembling front drive shaft Page 2 of 8
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Information
Component overview
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1) Danger of injury.
Tools
Tools
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ATTENTION
Increased risk of accidents during disassembly work from falling parts.
Danger of injury and damage.
The joint on the transmission side and joint pin on the wheel side of the front axle can be replaced. The entire
drive shaft must be replaced if the profile shaft is defective.
Removing cap
3. Remove clamp and hose clamp at the boot -arrows- . If you intend to
re-use the boot, make sure not to damage it.
4. Position inner joint on the ball hub (star-shaped inner ring). Do not
put it on the sheetmetal part! Press the joint off the profile shaft on a
hydraulic press.
Removing clamps
5. Release hose clamps and boots and take them off the profile shaft.
Removing boots
6. Clamp the drive shaft (use aluminium protective jaws). Position an aluminium mandrel on the ball hub (star-
shaped inner ring) -arrow- and remove the joint pin (outer joint) by hitting it several times with a hammer
-see figure- .
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Removing joint
Assembling drive shaft
ATTENTION
Increased risk of accidents during disassembly work from falling parts.
Danger of injury and damage.
Before fitting the joint, slide all boots, hose clamps and other clamps on to the drive shaft.
Use new circlips and ensure that they are seated correctly.
Note
Before regreasing, remove excess grease with a lint-free cloth. Do
not use cleaning agents on the joints (grease thinners!).
Make sure that only a small amount of grease gets into the bellows.
This grease is not relevant for the actual lubrication of the joint.
Regreasing joints:
Regrease the joints with special grease (refer to Spare Parts Catalogue).
The original grease quantities for the individual joints are specified in the
following table. Fitting the joint
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3. Fit the large hose clamps for the two boots. The hose clamp lug - on
the transmission side - must be positioned between two bores on the
joint.
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Fitting cap
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing front wheel bearing housing (wheel carrier) Page 2 of 9
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing front wheel bearing housing (wheel carrier) Page 3 of 9
hub.
Preliminary work
Preliminary work
1. Remove axle nuts (wheel-side drive shaft fastening). Operate the brake whilst doing so (2 workers required).
2. Raise the vehicle→ Lifting the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the
vehicle [9PAAJ1] and remove wheel → 440519 Removing and installing wheel - section on "Removing".
Tools
Tools
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Note
Remove the two wire retainers on the wheel bearing housing (M6 screw). Disconnect speed sensor plug.
After removing the wheel bearing housing, place the input shaft in such a way that the inner ball joint is not
overstretched.
Drive shafts must not be left hanging from the joint stop.
1. Remove the brake calliper → see figure and the two brake line
holders and pull plug off the speed sensor. Secure the brake calliper
at a suitable position in the wheel well (do not open the brake
system!).
2. Fix -upper trailing arm- with spring compressor VW 552 (vehicle in illustration with conventional
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suspension). This involves tensioning axle strut slightly because top ball joint can otherwise get damaged.
When doing this, insert tension jack into the top opening of wheel house (double panel) and in the axle strut.
4. Loosen the fastening nuts from the -bottom ball joint- and press off
with the press-out tool T10187. When doing this, leave fastening
nut flush on ball journal, so as not to damage the thread.
6. Use a suitable -lift with rubber base- (to prevent slipping) to raise
the wheel bearing housing to a position at which the screw can be
unscrewed easily.
7. Press out the tie rod on the wheel bearing housing using the press-
out tool T10187.
8. Press out the ball joint on the control arm using the press-out tool
T10187 and secure the wheel bearing housing so that it does not fall
down (a second worker is required for this!). Pull the wheel bearing
housing out of the lower ball joint and remove it.
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ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
Note
The entire threaded joints of the axle must be tightened in vehicle
position. Vehicle position means: vehicle standing on the wheels, or
the wheel suspension is raised with a universal vehicle lift. Dimension
-X- , from → Control value: 502 mm +/-10 mm corresponds to
vehicle position.
Replace all expansion screws (screws which are fitted with torque angle tightening procedure).
Make sure the bevel pinions from the ball joints are clean. Clean with a lint-free cloth as necessary. Do not
use cleaning agent.
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Removing and installing front wheel bearing housing (wheel carrier) Page 8 of 9
1. Insert the wheel bearing housing on the lower ball joint and position the input shaft (a second worker is
required). Remove the wire between the spring strut prongs. Remove drive shaft protection.
2. Mount the wheel bearing housing on the upper control arm. Fit tie rod.
3. Grease the mounting-face ring of the axle nut with a little Optimoly
TA aluminium paste. Screw on the axle nuts. If it is not possible to
push the shaft in all the way, use the assembly fixture T10206 to
pull the drive shaft in.
4. Attach the two wire retainers and the -speed sensor plug- .
5. Screw the spring strut to the lower axle strut.
Subsequent work
Subsequent work
as of MY 2003
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Removing and installing front wheel bearing housing (wheel carrier) Page 9 of 9
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Removing and installing front wheel bearing Page 2 of 11
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Removing and installing front wheel bearing Page 3 of 11
Tools
Tools
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-A- - Tubular piston cylinder VAS 6178 (The tubular piston cylinder is used together with the pneumatic
hydraulic pump.)
-1- - T10205/1 grip piece from attachments T10205 (To press the wheel hub out of the wheel bearing.)
-2- - T10205/2 bell from attachments T10205 (To press out the wheel hub. To pull off the wheel bearing inner
race from the wheel hub, use together with separator 12 - 115 mm ø No. 111.)
-3- - T10205/3 pressure piece from attachments T10205 (To press out the wheel hub.)
-4- - T10205/4 mounting from attachments T10205 (To press out the wheel bearing.)
-5- - T10205/5 pipe from attachments T10205 (To press out the wheel bearing.)
-6- - T10205/6 pressure disc from attachments T10205 (To press out the wheel bearing. And to press in the
wheel hub.)
-7- - T10205/7 pressure piece from attachments T10205 (To press in the wheel bearing.)
-8-1- - T10205/8-1 threaded rod from attachments T10205 (Used in the tubular piston cylinder -A- .)
-8-2- - T10205/8-2 threaded nut from attachments T10205 (Used on the threaded rod -8-1- .)
-9- - T10205/9 pressure piece from attachments T10205 (To press in the wheel bearing.)
-10- - T10205/10 pressure piece from attachments T10205 (To press in the wheel hub.)
-13- - T10205/13 push button from attachments T10205 (Used in the tubular piston cylinder -A- .)
Information
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ATTENTION
Increased danger of accident when handling hydraulic presses.
Danger of crushing and material damage if the wheel carrier is raised improperly.
Watch out for parts falling when working with the hydraulic cylinder.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
→ Vehicle may not be moved if drive shafts have not been fitted and tightened.
Note
The wheel bearing is removed with the wheel bearing housing installed.
1. Remove the corresponding hub cap with puller hook 92291 and release the axle nut (fastening nut) before
lifting the vehicle. Operate the brake whilst doing so (2 fitters required).
3. Remove the axle nut (fastening nut). Perform work up to step 7 in Chapter Removing and installing front
drive shaft. → 404119 Removing and installing front drive shaft - chapter on "Removing".
4. Remove the two holders (brake hose, combination wire) on wheel bearing housing.
5. Remove the wheel speed sensor. → 451119 Removing and installing front rpm sensor - chapter on
"Removing"
6. Remove the brake disc. → 465019 Removing and installing front brake disc - chapter on "Removing"
7. Press out the wheel carrier on the top axle strut (top ball joint) with
press-out tool T10187.
8. Undo the drive shaft on the transmission. To do this, first fitter must
pull out top wheel carrier outwards carefully, so that the second fitter
can carefully pull out the drive shaft.
9. Insert the wheel bearing housing again on the top axle strut (top ball
joint) and screw on nut.
11. Secure the grip pieces (2 half shells) T10205/1 (from attachments T10205 ) with several wheel bolts behind
the wheel hub. → see figure
12. Insert the T10205/2 bell (from attachments T10205 ) into the provided groove in the correct position. → see
figure
13. Insert the tubular piston cylinder vas 6178. Position the T10205/3 pressure piece (from attachments
T10205 ) and the 8-2 nut for the threaded rod (from attachments T10205 ). Press out the wheel hub. → see
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figure
It should be ensured that the separator is not pressing on the seat of the
bearing inner race on the wheel hub → see figure .
15. Press inner race off the wheel hub. To do this, position the T10205/2 bell (from attachments T10205 )
without the grip piece. Insert the tubular piston cylinder vas 6178. Position the T10205/3 pressure piece
(from attachments T10205 ) and the 8-2 nut for the threaded rod (from attachments T10205 ). → see figure
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Removing and installing front wheel bearing Page 8 of 11
18. Press out the wheel bearing. To do this, position the T10205/5 and
T10205/4 (from attachments T10205 ) in correct position on the
wheel bearing housing. Insert the tubular piston cylinder vas 6178.
Position the T10205/6 (from attachments T10205 ) and the 8-2 nut
for the threaded rod (from attachments T10205 ). → see figure
ATTENTION
Increased danger of accident when handling hydraulic presses.
Danger of crushing and material damage if the wheel carrier is raised improperly.
Watch out for parts falling when working with the hydraulic cylinder.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
→ Vehicle may not be moved if drive shafts have not been fitted and tightened.
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Note
The wheel bearing must not come into contact with magnetic objects (e.g., magnetic screwdriver, magnet).
Replace all expansion screws (screws which are fitted with torque
angle tightening procedure).
Make sure the bevel pinions from the ball joints are clean. Clean with a lint-free cloth as necessary. Do not
use cleaning agent.
Check that the bearing seat -arrow- (in rear axle figure) is clean and the
surface is in good order. There must not be scores, grooves or
deformations.
Insert the wheel bearing with the magnetic multiple-pole ring to the drive
shaft. Check the magnetic side (e.g., with a paper clip). Do not use
magnets or screw drivers to check!
2. Position the -wheel bearing in the wheel bearing housing- in the correct position. Position the T10205/7
pressure piece (from attachments T10205 ) in the correct position on the wheel bearing. Insert the tubular
piston cylinder vas 6178. Position the T10205/9 pressure piece (from attachments T10205 ) and the 8-2
nut for threaded rod (from attachments T10205 ) in the correct position. Mount wheel bearing. Shortly
before the stop, the applied force will be between 35 kN and 60 kN. Do not exceed the maximum assembling
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3. Position the -snap ring- with the opening facing downward. When
the Seger ring is fitted correctly, -dimension X- is at least 15 mm. →
minimum dimension: 15 mm If this dimension is not reached, the
Seger ring must be fitted again. If necessary, carefully press the
wheel bearing again.
Carry out a close visual inspection of the seat of the wheel hub. There
must not be scores, grooves or similar deformations on the hub.
5. Position the -wheel hub- in the correct position. Position the T10205/10 pressure piece (from attachments
T10205 ) in the correct position on the wheel hub. Insert the tubular piston cylinder vas 6178. Position the
T10205/6 pressure piece (from attachments T10205 ) and the 8-2 nut for threaded rod (from attachments
T10205 ) in the correct position. Pull in the wheel hub. Shortly before the stop, the applied force will be
between 9 kN and 35 kN. Do not exceed the maximum assembling force at the stop. → assembling force:
40 KN
6. Fit drive shaft. → 404119 Removing and installing front drive shaft - section on "Installing"
7. Press out the wheel carrier on the top axle strut (top ball joint).
8. Fit the brake disc. → 465019 Removing and installing front brake disc - section on "Installing"
9. Fit the wheel speed sensor. → 451119 Removing and installing front rpm sensor - section on "Installing"
10. Fit the two holders (brake hose, combination wire) on wheel bearing housing.
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Subsequent work
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Raise the vehicle.→ Lifting the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the
vehicle [9PAAJ1]
Remove engine guard. → 108019 Removing and installing engine guard - section on "Removing"
Removing stabilizer
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-1- - Stabiliser
-2- - Stabiliser bearing
-3- - Clamp
-4- - Fastening screws
-5- - Connecting rod
-6- - Fastening screw
-7- - Fastening screw
-8- - Fastening nut
ATTENTION
Danger of injury and material damage if the wheel carrier is raised incorrectly.
Crushing and other injuries can occur due to slipping parts.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When
raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
1. Release connecting rod right and left. When doing this, raise wheel carrier to the extent that connecting rod
fastening pin can be taken out easily. Use a -lift with rubber base- in order to prevent slipping.
3. Mark the installation position -arrow- of the -halves of the stabiliser bearing- for the stabiliser with a paint
marker.
4. Carefully pull out the anti-roll bar.
Installing stabilizer
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-1- - Stabiliser
-2- - Stabiliser bearing
-3- - Clamp
-4- - Fastening screws
-5- - Connecting rod
-6- - Fastening screw
-7- - Fastening screw
-8- - Fastening nut
ATTENTION
Danger of injury and material damage if the wheel carrier is raised incorrectly.
Crushing and other injuries can occur due to slipping parts.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When
raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
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Note
The entire threaded joints of the axle must be tightened in vehicle
position. Vehicle position means: vehicle standing on the wheels, or
the wheel suspension is raised with a universal vehicle lift. Dimension
-X- , from → Control value: 502 mm +/-10 mm corresponds to
vehicle position.
Replace all expansion screws (screws which are fitted with torque angle tightening procedure).
Make sure the bevel pinions from the ball joints are clean. Clean with a lint-free cloth as necessary. Do not
use cleaning agent.
1. Mount the -halves of the stabiliser- on the previously applied marking on the stabiliser. The larger outer
diameter of the halves of stabiliser bearing is on the wheel side.
3. Position anti-roll bar and fit clamps using the four fastening screws.
Subsequent work
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Subsequent work
Attach engine guard. → 108019 Removing and installing engine guard - section on "Installing"
Lower the vehicle.→ Lifting the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the
vehicle [9PAAJ1]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Connect the Porsche System Tester → see figure and in the menu
select >> Offroad Stabi (ORS) >> Drive links >> Clock valve VA or
valve HA <<.
Installation Location:
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Front stabiliser
Installation Location:
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WARNING
Danger of accident. The Offroad Stabilizer System (ORS) operates at an overpressure of up to 165 bar. If
the ORS is not depressurised, movements may occur on the wheel carrier under certain circumstances
(e.g. the off-road stabilisers are disengaged when the vehicle is lifted, the switch on the centre console is
pressed and the wheel carrier is also lifted).
The stabilizer can close quickly. Thus there is the danger of crushing in the area of the stabilizers
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and wheel carriers. Danger of injury and material damage if the wheel carrier is raised incorrectly.
→ Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
button must be OFF . If the indicator light is on, follow the following procedure: Switch on the ignition and
engage the road driving programme >> High Range <<. The stabilizers must audibly engage.
→ Before working on the ORS, depressurise the system. To do this, close the Porsche System Tester and
select in the menu >> Offroad Stabi (ORS) >> Drive links >> clock valve VA or valve HA <<. The valve
clocks (audibly) until the procedure is finished.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When
raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
1. Release connecting rod right and left. When doing this, raise wheel
carrier to the extent that connecting rod fastening pin can be taken
out easily. Use a suitable lift with rubber base → see figure in order
to prevent slipping.
2. Loosen the 2 lines (centre in Figure) → see figure and counter with
an open-ended wrench. Seal the lines with suitable plugs. Remove
the plug (left arrow) → see figure .
3. Undo the 4 fastening screws and remove the clamps.
Installation Location:
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Front stabiliser
Installation Location:
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WARNING
Danger of accident. The Offroad Stabilizer System (ORS) operates at an overpressure of up to 165 bar. If
the ORS is not depressurised, movements may occur on the wheel carrier under certain circumstances
(e.g. the off-road stabilisers are disengaged when the vehicle is lifted, the switch on the centre console is
pressed and the wheel carrier is also lifted).
The stabilizer can close quickly. Thus there is the danger of crushing in the area of the stabilizers
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and wheel carriers. Danger of injury and material damage if the wheel carrier is raised incorrectly.
→ Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
button must be OFF . If the indicator light is on, follow the following procedure: Switch on the ignition and
engage the road driving programme >> High Range <<. The stabilizers must audibly engage.
→ Before working on the ORS, depressurise the system. To do this, close the Porsche System Tester and
select in the menu >> Offroad Stabi (ORS) >> Drive links >> clock valve VA or valve HA <<. The valve
clocks (audibly) until the procedure is finished.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When
raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
1. Release connecting rod right and left. When doing this, raise wheel
carrier to the extent that connecting rod fastening pin can be taken
out easily. Use a suitable lift with rubber base → see figure in order
to prevent slipping.
2. Loosen the 2 lines (centre in Figure) → see figure and counter with
an open-ended wrench. Seal the lines with suitable plugs. Remove
the plug (left arrow) → see figure .
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Installation Location:
Front stabiliser
Installation Location:
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ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
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→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
Note
Visually inspect all parts.
Replace all expansion screws (screws which are fitted with torque angle tightening procedure).
1. Mount the halves of the stabiliser bearing → see figure in the correct
position on the stabiliser. In the correct position means: The larger
outer diameter is on the wheel side.
4. Fit the 2 lines (centre in Figure) → see figure and counter with an open-ended wrench. Plug in the plug (left
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Subsequent work
Bleed the Offroad Stabilizer System . → 407707 07 Bleeding the Offroad Stabilizer System (ORS)
Fit the engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Preliminary work
Remove wheel. → 440519 Removing and installing wheel - chapter on "removing"
Note
The steel springs do not apply for the Cayenne Turbo.
Standard Cayenne Turbo equipment: Air springs with level control and vertical adjustment.
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ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle
position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard
rubber) .
→ Do not damage the brake cover plate.
1. Lift wheel carrier carefully to facilitate removal. Use a suitable lift with rubber base → see figure in order to
prevent slipping.
3. Fix upper axle strut with spring compressor VW 552. This involves tensioning the axle strut slightly
because otherwise the top ball joint can be damaged. When doing this, the spring compressor VW 552
→ see figure is engaged in the upper opening of the wheel housing (double panel) and in the axle strut and
pre-tensioned with the nut. This is only necessary if the same control arm is reinstalled.
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6. Push protective tube 44 -A- over drive shaft. Release drive shaft at
transmission flange and lay down carefully. Use suitable base.
7. Release holder for brake line/combination wire at the top on the wheel carrier.
8. Press out ball joint of wheel carrier tie rod with press-out tool T10187 -B- . Counter with screwdriver 9546
-C- .
9. Press out ball joint of top axle strut of wheel carrier with press-out tool T10187 -B- . Counter with
screwdriver 9546 -C- .
10. Remove spring compressor VW 552 -D- , release the 4 M8 fastening nuts from mounting saddle and
carefully remove spring strut.
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Note
The steel springs do not apply for the Cayenne Turbo.
Standard Cayenne Turbo equipment: Air springs with level control and vertical adjustment.
ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
Note
The entire threaded joints of the axle must be tightened in vehicle position. Vehicle position means: vehicle
standing on the wheels, or the wheel suspension is raised with a universal vehicle lift. Dimension -X- , from
→ Control value: 502 mm +/-10 mm corresponds to vehicle position.
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Replace all expansion screws (screws which are fitted with torque
angle tightening procedure).
Make sure the bevel pinions from the ball joints are clean. Clean with
a lint-free cloth as necessary. Do not use cleaning agent.
1. Carefully insert the spring strut and tighten to mounting saddle (four
M8 fastening nuts) with the prescribed tightening torque.
2. Fix upper axle strut with spring compressor VW 552. This involves
tensioning the axle strut slightly because otherwise the top ball joint
can be damaged. When doing this, the spring compressor VW 552
→ see figure is engaged in the upper opening of the wheel housing
(double panel) and in the axle strut and pre-tensioned with the nut.
3. For easy fitting, slightly raise wheel carrier with a suitable lift so that
upper ball pin can be inserted. Use a suitable lift with rubber base
→ see figure in order to prevent slipping.
6. Mount the mount for brake line/combination wire at the top on wheel
carrier.
Subsequent work
Mount wheel . → 440519 Removing and installing wheel - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
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C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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Disassembling and assembling front spring strut (steel springs) Page 2 of 10
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
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Disassembling and assembling front spring strut (steel springs) Page 3 of 10
Information
Component overview
Standard Cayenne Turbo equipment: Air springs with level regulation and vertical adjustment.
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Disassembling and assembling front spring strut (steel springs) Page 4 of 10
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Mounting instructions
ATTENTION
Increased risk of accidents due to spring tensioning.
Danger of injury and damage from springs jumping out.
Note
Observe the correct allocation (engine variant) when installing new coil springs and/or shock absorbers.
Observe allocation of the bottom spring plate according to the coil spring tolerance group.
1. Clamp the spring strut at a suitable place in the vice (use jaw liners).
2. Tension the coil springs -see figure- using spring clamp for spring struts NR.121 until the piston rod is
relieved.
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Disassembling and assembling front spring strut (steel springs) Page 6 of 10
Spring clamp
Allocation of coil spring and bottom support
The bottom support (spring plate) is allocated according to the coil spring tolerance group.
The colour coding -arrow- of the coil spring is located at the middle of the
coil spring and is indicated by coloured dots → Distinguishing feature and
allocation of coil springs and shock absorbers.
The coil springs are allocated using coloured dots -arrow- . Yellow is used for the Cayenne and gold for the
Cayenne S → Allocation of coil spring and bottom support. Refer to the Parts Catalogue for the allocation.
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Disassembling and assembling front spring strut (steel springs) Page 7 of 10
The shock absorbers are allocated using the spare part numbers and the
model specification. At present, two different shock absorbers, right and
left, are used on the front axle of the Cayenne and Cayenne S. Refer to
the Parts Catalogue for the allocation.
1. Place the cap -1- , rubber stop -2- and protective sleeve -3- together
as follows before pushing them on to the piston rod:
– Push the rubber stop -2- up fully into the protective sleeve -3- .
2. Place the bottom concave washer (grey) -see figure- together with the bottom support -see figure- at the
correct position (not twisted).
At the correct position means that the two individual parts are fitted precisely together.
3. Place the top concave support -see figure- together with the top support -see figure- at the correct position
(not twisted).
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Disassembling and assembling front spring strut (steel springs) Page 8 of 10
Fitting bottom concave washer into Fitting cap into protective sleeve
bottom support
At the correct position means that the two individual parts are fitted
precisely together.
Assembly
Assembly
ATTENTION
Increased risk of accidents due to spring tensioning.
Danger of injury and damage from springs jumping out.
1. Position the bottom support and bottom concave washer assembly at the correct position on the shock
absorber.
At the correct position means that the two individual parts are fitted precisely together.
2. Position the pre-tensioned coil spring precisely at the stop in the bottom concave washer -arrow- .
3. Slide the protective sleeve/stop buffer/cap assembly loosely onto the piston rod.
4. Position the top concave support assembly with the top support.
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Disassembling and assembling front spring strut (steel springs) Page 9 of 10
Marking and fitting top concave Coil spring stop in bottom concave
support with top support at correct washer
position
– Position the top spring plate -arrow- precisely at the coil spring stop.
6. Once the mount is positioned, fit the new lock nut. Screw the lock nut
onto the piston rod until approx. 1 to 2 threads are visible above the
lock nut. Then tighten with double-arm torque wrench 15 - 65 Nm
(48 ftlb.) NR.93.
– Push the protective sleeve -arrow- down fully and clip it to the shock absorber with the cap (audible click).
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Disassembling and assembling front spring strut (steel springs) Page 10 of 10
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
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Component arrangement - Off-Road Stabiliser System (ORS) Page 2 of 4
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
As an option, the running gear of the Cayenne can be equipped with an Offroad Stabiliser System (ORS).
The ORS enables optimum traction on the front and rear axle in off-road operation. The stabiliser rate is lowered
to a minimum. The main part of the ORS is centrally arranged, hydraulically activated actuators. There are claw
clutches in the actuators which enable the separation of the stabiliser arm with a swivel range of approx. ±30°.
A coil spring in the actuators is used as an additional mechanism for locking the clutches. This means that if there
is pressure loss or if there are electrical defects, the clutches of the stabilisers close automatically.
When the vehicle is started, the ORS system is automatically in Onroad mode. The system can only be switched
on and off in the offroad programme >> Low Range << using the >> Release for the stabiliser (button) << in the
selector switch on the centre console. The system status is shown on the display in the instrument cluster.
If the car is driven on a steep incline or if a speed of 50 Km/h is exceeded, the stabilisers are switched to Onroad
mode, independent of the switching commands of the driver.
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Component arrangement - Off-Road Stabiliser System (ORS) Page 3 of 4
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Component arrangement - Off-Road Stabiliser System (ORS) Page 4 of 4
console.
-E- Control module. 1 On the rear wall
in the spare
wheel well.
-F- Dipstick. 1 Behind the
cover in the D-
pillar.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
file://E:\POSES\data\rl\2\9PA\4616582_KDNum_0.htm 5/20/2011
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. For vehicles with level adjustment: Switch off level adjustment → Lifting the vehicle [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1].
Tools
-A- - Mounting frame (See Workshop Equipment Manual, Chapter 3.0)
-11- - Take-up point for rear axle housing
-22- - Take-up point for rear axle housing
These removal and installation instructions apply to vehicles with level adjustment and steel springs. The points
relating to level adjustment are not relevant for vehicles with steel springs.
ATTENTION
Increased risk of accident when working on the exhaust system, the
rear axle and the vibration dampers.
Possible danger of injury or damage.
1. Remove the combination wires at the joint (brake wear, CDC sensor) -1- and then unclip the rubber sleeves
-2- from the sheetmetal holders.
2. Undo the brake caliper and hang it in a suitable place in the wheel housing.
Note
Always wear safety goggles and gloves when working on vehicles
with level adjustment.
Mark the installation position (e.g. with a felt-tip pen) when removing
the cardan shaft.
Mark the installation position (e.g. with a felt-tip pen) when removing
the rear axle housing.
The take-up points 11 and 22 are required for removing the rear axle. Remove the remaining take-up points.
3. In vehicles with level adjustment, disconnect the air connection to the spring struts -arrow- (front axle
connection shown here).
5. Unclip both brake cables from the Quickfit attachment and remove them from the cable guides → 467919
21 Removing and installing (rear) brake cable for foot-operated parking brake - chapter on "removing". Hang
the cables in a suitable place to prevent damage.
7. Make sure that the cardan shaft does not become kinked (tie it up, -arrow- ).
8. Disconnect the plug connections for the level adjustment and
headlight levelling systems ( -arrow- ). On vehicles with differential
lock, disconnect the plug connection on the rear axle transmission.
10. Position the mounting frame correctly on the → see figure lifting
platform.
11. Position the lifting platform with the → see figure mounting frame under the rear axle housing.
12. Push into the take-up points -arrows- provided. The -arrows- show
the take-up points for the mounting frame in the rear axle housing
(view from below here).
14. Loosen the rear axle housing ( -arrows- ) . Lower the rear axle while
taking care not to damage adjacent components.
15. Remove the stabilizer on the vibration dampers and on the rear axle
housing.
Note
Get a second worker to help to remove the wheel carrier with
accessories and the rear axle transmission.
18. Loosen the triangular control arms, control arms and tie rods on the rear axle housing. Remove the wheel
carriers with triangular control arms, control arms, tie rods and half-shafts.
19. Remove the rear axle transmission by unscrewing the screws on the rear axle housing and lifting out the
transmission.
ATTENTION
Increased risk of accident when working on the exhaust system, the rear axle and the vibration dampers.
When filling the air spring struts, the vehicle lifts. Damage due to raising the wheel carrier incorrectly.
Possible danger of injury or damage (crushing, cuts).
Note
Before installing, give the parts a visual check.
Position the rear axle housing with respect to the body at the markings made previously.
Replace all fastening nuts and all expansion screws (screws which are fitted with torque angle tightening
procedure).
Do not raise the wheel suspension higher than the normal vehicle
position (vehicle resting on wheels). When raising the suspension,
use a suitable intermediate layer (hard rubber).
Calibrate the steering angle sensor with the Porsche System Tester → 456005 Initialising and calibrating
steering angle sensor.
2. Pre-fit the accessories on the rear axle housing. Get another worker
to help. A final tightening of the screw connections must be
performed when the vehicle is in normal vehicle position.
3. Position the rear axle housing and damper housing back in the
original, marked installation position and tighten; be careful not to
damage adjacent parts -arrows- .
4. Fit the half-shafts, stabilizer, plug connections and the bleeding line
on the rear axle transmission.
5. Fit the cardan shaft, brake cables, brake calipers and combination
connectors. Follow correct cable routing.
6. On vehicles with level adjustment, attach the air connection to the
spring struts.
Subsequent work
Subsequent work
1. Fit rear muffler → 260119 Removing and installing exhaust system - chapter on "installing".
3. To fill the level adjustment system, use the Porsche System Tester. To do this, select the Fill air suspension
menu item in the Level adjustment system. Switch on level adjustment → Lifting the vehicle [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1].
4. Perform suspension alignment → Suspension alignment, complete and calibrate → 456005 Initialising and
calibrating steering angle sensor.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Switch off level adjustment. → 40 Lifting the vehicle
On vehicles with ORS, depressurise the system using the PIWIS Tester.
Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
button must be OFF. If the indicator light is on, follow the following procedure: Switch on the ignition and
engage the road driving programme >> High Range <<. The anti-roll bars must engage audibly.
Before working on the ORS, always depressurise the system! To do this, close the PIWIS Tester and select
>> Offroad Stabi (ORS) >> Drive links >> Clock FA valve or RA valve <<. The valve clocks (audibly) until the
procedure is finished (approx. 20 seconds).
Tools
Tool overview for suspension subframe bearings assembly fixture T10301
-A- - → Hydraulic cylinder VAS 6178 (The hydraulic cylinder is used together with the → foot pump VAS 6179
and the → pressure gauge with connecting cable VAS 6179/1 -B- .)
-1- - Threaded rod (Inserted into the tubular piston cylinder -A- .)
-2- - Threaded nut (Screwed onto the threaded rod -1- .)
-3- - Pipe (For pressing out the suspension subframe bearings.)
-4- - Ring (For pressing out the suspension subframe bearings.)
-5- - Press-out plate (For pressing out the suspension subframe bearings.)
. -6- - Pressure piece (For pressing in the suspension subframe bearings.)
-7- - Press-in plate (For pressing in the suspension subframe bearings.)
-8- - Ring (For pressing out the suspension subframe bearings.)
-9- - Spacer sleeve (For pressing out the suspension subframe bearings together with pipe -3- .)
-10- - Pressure piece (For pressing in the suspension subframe bearings.)
-11- - Spacer sleeve (For pressing in the suspension subframe bearings.)
Replacing
WARNING
Risk of accidents! The Offroad Stabilizer System (ORS) operates at an overpressure of up to 165 bar.
Under certain conditions, motions can occur on the wheel carrier (e.g. if the Offroad stabilizers are
disengaged when lifting, the button is pressed on the centre console, and the wheel carrier is also
raised). The stabilizer can close quickly.
Danger of crushing in the area of the stabilizers and wheel carriers. Risk of injury and material
damage due to raising the wheel carrier incorrectly.
→ Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
button must be OFF. If the indicator light is on, follow the following procedure: Switch on the ignition and
engage the road driving programme >> High Range <<. The anti-roll bars must engage audibly.
→ Before working on the ORS, always depressurise the system! To do this, close the PIWIS Tester and select
>> Offroad Stabi (ORS) >> Drive links >> Clock FA valve or RA valve <<. The valve clocks (audibly) until the
procedure is finished (approx. 20 seconds).
Note
Front rear-axle bearings: The cardan shaft must not touch the mounting
face when lowering the suspension subframe! -Arrow-
3. Loosen the threaded joint at the bearing and carefully lower the gear
support until there is sufficient clearance for using the tool.
ATTENTION
Danger of injury due to falling tools.
Danger of crushing and deformation
Note
Hold the hydraulic cylinder VAS 6178 tightly while pressing it out.
Note
When inserting the bearing, make sure that the two bores are pointing in
an imaginary line in the direction of travel.
9. Attach the tools as shown in the illustration and press in the bearing.
Note
Observe correct tightening torques.
10. Carefully lift the suspension subframe until the installation position is
reached. Fit threaded joint on suspension subframe bearing.
11. For vehicles with Offroad Stabilizer system (ORS): Clip the lines into
the holder on the body.
Subsequent work
Subsequent work
1. Fit rear silencer. → 260119 Removing and installing exhaust system
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Remove wheel → 440519 Removing and installing wheel - chapter on "Removing"
2. Release tie rod at suspension subframe (eccentric screw) and at wheel carrier. Pull out tie rod.
To make removal easier, raise wheel carrier slightly with universal jack!
→ see figure Use rubber base to prevent wheel carrier from slipping!
Note
The left-hand and right-hand tie rods are identical. Ensure correct installation position. The tapered end must
be secured on the wheel carrier in the direction of travel.
The entire threaded joints of the axle must be tightened in vehicle
position. Vehicle position means: vehicle standing on the wheels, or
the wheel suspension is being raised with a universal vehicle lift.
Dimension -X- , from lower edge of wing to middle of axle 506 mm
±10 mm corresponds to vehicle position.
Replace all expansion screws (screws which are fitted with torque
angle tightening procedure).
Subsequent work
Perform a suspension alignment after installation → 44 Complete suspension alignment.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Remove wheel . → 440519 Removing and installing wheel - chapter on "Removing"
2. Remove eccentric screw and fastening screw from trailing arm to suspension subframe.
3. Remove trailing arm carefully in downward direction and underneath drive shaft.
ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Danger of injury and risk of damage to property.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
Note
Visually inspect all parts.
Replace all expansion screws (screws which are fitted with torque angle tightening procedure).
Check vehicle setting values after repair and adjust if necessary. → 44 Complete suspension alignment
2. Position trailing arm in wheel carrier and secure against falling with
fastening screw and nut.
3. Tighten fastening nut from trailing arm to wheel carrier with specified tightening torque.
Subsequent work
Fit wheel → 440519 Removing and installing wheel - chapter on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
General
The bearing for the trailing arm must be pressed in separately when replacing the wheel bearing housing. The
wheel bearing housing is not supplied with the bearing as a spare part.
Tools
Preliminary work
1. Raise the vehicle → 40 Lifting the vehicle.
2. Remove the wheel. → 440519 Removing and installing wheel - chapter on "Removing".
ATTENTION
Increased risk of accidents when working with hydraulic presses - danger of crushing, deformation of
components.
Risk of injury if the threaded rod in the tubular piston cylinder breaks because of pressure or
traction.
Possible danger of damage or injury.
→ The worker must always stand away from the direction of pressure or traction on the threaded rod when
using the tubular piston cylinder.
→ Position pressure pieces correctly and ensure that they are seated properly.
→ Watch out for falling parts when working with hydraulic presses.
→ Danger of injury and material damage if the wheel carrier is raised incorrectly.
→ Do not damage the brake cover plate.
Note
The bearing is replaced using the assembly fixture T10230.
3. Insert tyre mounting lever between the wheel bearing housing and the trailing arm -see figure- . Press the
trailing arm down until the bearing is freely accessible. Do not damage the brake cover plate.
4. Press the lower trailing arm down further until a suitable spacer -see figure- (e.g. wooden block) can be
inserted (makes removal easier).
5. The pressure pieces and the tubular piston cylinder VAS 6178 are used for removal. No. 13 is screwed into
the tubular piston cylinder. No. 2 is screwed on to the threaded rod and positioned in No. 13 for pressing out
the bearing.
T10230/2
T10230/3
T10230/4
T10230/5
T10230/6
T10230/7
T10230/13
T10230/14
T10230/15
Get a second worker to help when working on the wheel bearing housing.
6. Position the tubular piston cylinder -see figure- and pre-tension
slightly to prevent the pressure pieces from slipping out of place.
Check the position of the pressure pieces again.
ATTENTION
Increased risk of accidents when working with hydraulic presses - danger of crushing, deformation of
components.
Risk of injury if the threaded rod in the tubular piston cylinder
breaks because of pressure or traction.
Possible danger of damage or injury.
→ The worker must always stand away from the direction of pressure
or traction on the threaded rod when using the tubular piston
cylinder.
→ Position pressure pieces correctly and ensure that they are seated
properly.
→ Watch out for falling parts when working with hydraulic presses.
→ Danger of injury and material damage if the wheel carrier is raised
incorrectly.
→ Do not raise the wheel suspension higher than the normal vehicle
position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard
rubber) .
→ Do not damage the brake cover plate.
Note
The entire threaded parts of the axle must be tightened in vehicle
position. Vehicle position means: vehicle standing on the wheels, or
the wheel suspension is raised using a universal vehicle lift.
Dimension -X- from lower edge of wing to middle of axle 506 mm ±10
mm corresponds to vehicle position.
1. To fit the new bearing use the -pressure pieces- and tubular
cylinder VAS 6178. No. 13 is screwed into the tubular piston cylinder.
No. 2 is screwed onto the threaded rod and positioned in No. 13 for
pressing in the bearing.
T10230/2
T10230/3
T10230/6
T10230/7
T10230/8
T10230/13
T10230/14
T10230/15
4. If the bearing for the axle strut is fitted cleanly, install the wheel
bearing housing in the bottom axle strut.
Subsequent work
Subsequent work
1. Fit brake caliper.→ 474119 Removing and installing rear brake caliper - chapter on "Installing".
2. Fit wheel → 440519 Removing and installing wheel - chapter on "Installing" .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
3. Remove rear muffler → 260119 Removing and installing exhaust system - chapter on "Removing".
Note
To prevent damage to the drive shaft, rear axle support side member or transmission flange, a protective
tube (shop-made) 00000 must be pushed over the drive shaft or the drive shaft must be secured.
During removal of the drive shaft, the wheel bearing housing remains in the vehicle and is swivelled outwards
at the top side.
1. Fit protective tube (shop made) 00000 for drive shaft. Release drive
shafts on inside at transmission (both sides) and -arrow- tie up, e.g.
with a tie-wrap. This will prevent damage to the drive shaft,
suspension subframe and transmission flange.
4. Using universal drive shaft/wheel hub puller as of model '86 NR.87-1, press out peg from the drive shaft.
5. Remove previously fitted tie-wrap. Carefully pull out the drive shaft to be replaced.
Installing rear drive shaft
Note
Screws are Dacromet-coated and must not be greased.
Grease the toothing of the drive shaft lightly with Optimoly HT.
To prevent damage to the drive shaft, wheel bearing housing or transmission flange, slide a protective tube
(shop-made) 00000 over the drive shaft.
Observe correct tightening torques. After tightening, loosen the connecting rod for the stabiliser 90 degrees,
and tighten again (settling behaviour of the ball joint!). → 420000 Tightening torques for rear axle
The parking brake is self-adjusting. If the basic setting of the parking brake is correct, further adjustment
operations on the parking brake lever or on the turnbuckle are not necessary.
Always check the bellows for damage and if necessary, replace them, if continuing to use the drive shaft.
1. Insert drive shaft and grease mounting-face ring of axle nut with a little
Optimoly TA aluminium paste. Screw on axle nut to prevent shaft from
slipping out. If the shaft cannot be pushed right in, use assembly
fixture T10206 to pull the drive shaft in. Protect the drive shaft. Tie up
drive shaft with a tie-wrap. This will prevent damage to the drive shaft,
suspension subframe and transmission flange.
Subsequent work
1. Push in rear final drive. Connect vent hose → 390119 Removing and installing rear final drive - chapter on
"Installing".
2. Fit rear muffler → 260119 Removing and installing exhaust system - chapter on "Installing" .
3. Mount wheel and tighten axle nut (vehicle on ground, also operate the brake - second fitter required).
9PAAD1, 9PAAD7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Component overview
1)
Tools
ATTENTION
Watch out for falling parts during disassembly work.
Possible danger of injury or damage.
Only the joint on the transmission side can be replaced on the rear axle. Otherwise the entire drive shaft must be
replaced.
Removing cap
3. Remove clamp and hose clamp at the boot -arrow- .
4. Position inner joint on the ball hub (star-shaped inner ring). Do not
put it on the sheetmetal part! Press the joint off the profile shaft on a
hydraulic press.
Removing clamps
5. Release hose clamps and boots and take them off the profile shaft.
Removing boots
Before fitting the joint, slide all boots, hose clamps and other clamps on to the drive shaft.
Use new circlips and ensure that they are seated correctly.
Note
Before regreasing, remove excess grease with a lint-free cloth. Do
not use cleaning agents on the joints (grease thinners!).
Make sure that only a small amount of grease gets into the bellows.
This grease is not relevant for the actual lubrication of the joint.
Regreasing joints:
Regrease the joints with special grease (refer to Spare Parts Catalogue).
The original grease quantities for the individual joints are specified in the
following table.
Removing joint
3. Fit the small hose clamps for the two boots. If the boots are fitted
correctly, the groove -A- will be visible.
Fitting cap
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
1) Danger of injury.
Tools
ATTENTION
Danger of injury. Look out for falling parts during disassembly work. Get another worker to help.
At the rear axle, only the joint on the transmission side can be replace. Otherwise the entire drive shaft must be
replaced.
5. Release hose clamps and boots and take them off the profile shaft.
ATTENTION
Danger of injury. Look out for falling parts during disassembly work. Get another worker to help.
Before fitting the joint, slide all boots, hose clamps and other clamps on to the drive shaft.
Use new circlips and ensure that they are seated correctly.
1. Clamp the drive shaft (use aluminium protective jaws). Position an aluminium mandrel on the ball hub (star-
shaped inner ring) and use forceful hammer blows to drive the -joint- up to the stop.
Note
Before regreasing, remove excess grease with a lint-free cloth. Do not use cleaning agents on the joints
(grease thinners!).
Make sure that only a small amount of grease gets into the bellows.
This grease is not relevant for the actual lubrication of the joint.
Regreasing joints:
Regrease the joints with special grease (refer to Spare Parts Catalogue).
The original grease quantities for the individual joints are specified in the
following table.
2. Fit the large hose clamps for the two boots. The hose clamp lug - on
the transmission side - must be positioned between two bores on the
joint.
3. Fit the small hose clamps for the two boots. If the boots are fitted correctly, the groove -A- will be visible.
4. Fill in the appropriate quantity of grease before fitting the cap (on the transmission side). Seal the sealing
surfaces with special sealant (see Spare Parts Catalogue). When fitting the cap, secure it in place with
-two pan-head screws- . Using a rubber hammer, alternate between striking one side of the cap and then
the other in order to fit it in the correct position.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Danger of injury and risk of damage to property.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
1. Loosen axle nuts (wheel-side drive shaft fastening). (Do not remove them!) This prevents the drive shaft
from slipping out when removing the wheel bearing housing. Actuate the brake while doing this.
2. Raise the vehicle→ Raising the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Raising the
vehicle [9PAAJ1] and remove wheel → 440519 Removing and installing wheel - chapter on "Removing".
Note
Before raising the vehicle, undo the drive shaft fastening at the wheel
side. Operate the brake whilst doing so (2 workers required).
1. Using universal drive shaft/wheel hub puller as of model '86 NR.87-1, push (press in) peg of drive shaft
approx. 20 mm - 25 mm into the wheel hub. When doing this, observe drive shaft clearance on the halfshaft
flange.
3. Open the plug connections on the wheel bearing housing and pull off the plugs.
4. Remove the brake calliper from the wheel bearing housing and suspend it at a suitable position in the wheel
arch (do not open brake hydraulics!).
5. Attach the foot-operated parking brake to the actuating mechanism using an auxiliary pin → see figure . To
do this, press the adjustment device -arrow- and relieve with a max. 3.5 mm drill (or similar) → 466019
Removing and installing actuator for foot-operated parking brake.
6. Unclip the brake cable from the Quickfit in the wheel bearing housing → 467919 Removing and installing
the (rear) brake cable for foot-operated parking brake. Remove screw plug -arrow- . The screw plug hides
the view of the Quickfit. The Quickfit is positioned at approx. 3 o'clock to the right and approx. 9 o'clock to the
left.
Note
The spring strut screws are
under tension. Carefully lever
out the lower spring strut
connection. Use a suitable lift
with a rubber base.
9. Remove the tie rod (toe control arm) at the wheel bearing housing.
10. Loosen the lower control arm -2- at the mount -1- and take out the
wheel bearing housing with the drive shaft (a second worker is
required for this).
11. Remove the axle nuts and take out the drive shaft.
ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Danger of injury and risk of damage to property.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
Note
The entire threaded joints of the axle must be tightened in vehicle
position. Vehicle position means: vehicle standing on the wheels, or
the wheel suspension is being raised with a universal vehicle lift.
Dimension -X- , from lower edge of wing to middle of axle 506 mm
±10 mm corresponds to vehicle position.
Grease the toothing of the drive shaft slightly with aluminium paste
Optimoly TA.
Drive shafts must not be left hanging from the joint stop. Support
wheel carriers.
Make sure the bevel pinions from the ball joints are clean. Clean with a lint-free cloth as necessary. Do not
use cleaning agent.
1. Insert the drive shaft into the wheel hub. If the shaft cannot be pushed right in, use → see figure assembly
fixture T10206 to pull the drive shaft in. Screw on the axle nuts in order to prevent the shaft from slipping
out.
2. Insert the wheel bearing housing (second worker required).
3. Fit the control arms, the spring strut and the brake calliper.
5. Mount the Quickfit. Make sure that the circlip is sealed and seated well and that the end of the cable
engages audibly.
Subsequent work
Subsequent work
1. Fit the axle nuts and the wheel → 440519 Removing and installing the wheel - chapter on "Installing".
2. Remove the auxiliary pin from the pedal module of the foot-operated parking brake.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
ATTENTION
Increased danger of accident when handling hydraulic presses.
Danger of crushing and material damage if the wheel carrier is raised improperly.
Watch out for parts falling when working with the hydraulic cylinder.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
→ Vehicle may not be moved if drive shafts have not been fitted and tightened.
The wheel bearing is removed with the wheel bearing housing installed.
1. Remove the corresponding hub cap with puller hook 92291 and release the axle nut (lock nut) before lifting
the vehicle. Operate the brake whilst doing so (second fitter required).
2. Raise the vehicle→ 40 Raising the vehicle and remove the relevant rear wheel → 440519 Removing and
installing wheel - chapter on "Removing".
3. Remove axle nut (lock nut) and the drive shaft → 422119 Removing and installing drive shaft - chapter on
"Removing" [9PAAE1 9PAAE7 9PAAF1]→ 422119 Removing and installing drive shaft - chapter on
"Removing" [9PAAD1 9PAAD7]→ 422119 Removing and installing drive shaft - chapter on "Removing"
[9PAAJ1]. To remove and install the drive shaft, the rear final drive must be removed → 390119 Removing
and installing rear final drive - chapter on ""Removing" [9PAAD1 9PAAD7]→ 390119 Removing and
installing rear final drive - chapter on ""Removing" [9PAAE1 9PAAE7 9PAAF1 9PAAJ1].
Tools
-A- - Tubular piston cylinder VAS 6178 (The tubular piston cylinder is used together with the pneumatic
hydraulic pump.)
-1- - T10205/1 grip piece from attachments T10205 (To press the wheel hub out of the wheel bearing.)
-2- - T10205/2 bell from attachments T10205 (To press out the wheel hub. To pull off the wheel bearing inner
race from the wheel hub, use together with separator 12 - 115 mm ø No. 111.)
-3- - T10205/3 pressure piece from attachments T10205 (To press out the wheel hub.)
-4- - T10205/4 mounting from attachments T10205 (To press out the wheel bearing.)
-5- - T10205/5 pipe from attachments T10205 (To press out the wheel bearing.)
-6- - T10205/6 pressure disc from attachments T10205 (To press out the wheel bearing. And to press in the
wheel hub.)
-7- - T10205/7 pressure piece from attachments T10205 (To press in the wheel bearing.)
-8-1- - T10205/8-1 threaded rod from attachments T10205 (Used in the tubular piston cylinder -A- .)
-8-2- - T10205/8-2 threaded nut from attachments T10205 (Used on the threaded rod -8-1- .)
-9- - T10205/9 pressure piece from attachments T10205 (To press in the wheel bearing.)
-10- - T10205/10 pressure piece from attachments T10205 (To press in the wheel hub.)
-13- - T10205/13 push button from attachments T10205 (Used in the tubular piston cylinder -A- .)
Removing
-1- - Wheel bearing housing (Carry out a close visual inspection of the seat of the wheel bearing. There must be
no scores, grooves or similar deformations.)
-2- - Wheel bearing (The wheel bearing can no longer be used once it is removed. Use a new wheel bearing. Do
not press on the inner race. Insert the wheel bearing with the magnetic multiple-pole ring towards the drive
shaft. Check the magnetic side (e.g., with a paper clip). Do not use magnets or screw drivers for the check!
-3- - Circlip (Use new circlip.)
-4- - Wheel hub (Pull off the inner race separately from the wheel bearing. Carry out a close visual inspection of
the seat of the wheel hub. There must be no scores, grooves or similar deformations on the hub.)
-5- - Axle nut (Lock nut - always replace. Grease contact surface with a little Optimoly TA. Tightening torque 370
ftlb.
1. Release brake caliper and hang at a suitable place in the wheel housing.
4. Remove wheel speed sensor -see illustration- → 451119 Removing and installing front speed sensor -
chapter on "Removing".
5. Remove wheel hub (tools).
6. Secure the grip pieces (two half shells) (from attachments T10205 )
with several wheel bolts behind the wheel hub.
8. Insert the tubular piston cylinder VAS 6178. Position the T10205/3 pressure piece (from attachments
T10205 ) and the T10205/8-2 threaded nut (from attachments T10205 ). Press out the wheel hub.
Ensure that the separating device does not press on the seat of the
bearing inner race on the wheel hub.
9. If the wheel hub is used again, remove the → see figure inner race of
the wheel bearing from the wheel hub. To do this, position the
separating device 12 - 115 mm ø NR.111 behind the inner race.
10. Press inner race off the wheel hub. To do this, position the T10205/2
bell (from attachments T10205 ) without the grip piece. Insert the
tubular piston cylinder VAS 6178. Position the T10205/3 pressure
piece (from attachments T10205 ) and the T10205/8-2 threaded nut
(from attachments T10205 ).
13. Press out the wheel bearing. To do this, position the T10205/4 mounting (from attachments T10205 ) and
the T10205/5 pipe (from attachments T10205 ) in the correct position on wheel bearing housing. Insert the
tubular piston cylinder VAS 6178. Position the T10205/6 pressure disc (from attachments T10205 ) and
the T10205/8-2 threaded nut (from attachments T10205 ).
Installing
Note
The wheel bearing must not come into contact with magnetic objects (e.g., magnetic screwdriver, magnet).
Grease the toothing of the drive shaft slightly with aluminium paste
Optimoly TA.
Drive shafts must not be left hanging from the joint stop! Tie up.
Check that the bearing seat -arrow- is clean and the surface is in good
order. There must be no scores, grooves or deformations.
Insert the wheel bearing with the magnetic multiple-pole ring to the drive
shaft. Check the magnetic side (e.g., with a paper clip). Do not use
magnets or screw drivers to check!
2. Position the → see figure wheel bearing in the wheel bearing housing
in the correct position. Position the T10205/7 pressure piece (from
attachments T10205 ) in the correct position on the wheel bearing.
Insert the tubular piston cylinder VAS 6178. Position the T10205/9
pressure piece (from attachments T10205 ) and the T10205/8-2
threaded nut (from attachments T10205 ) in the correct position.
Mount the wheel bearing. Shortly before the stop, the applied force
will be between 26 ftlb. and 44ftlb. The maximum assembling force
must not exceed 67 ftlb. at the stop.
3. Position the → see figure circlip with the opening facing downward.
When the Seger ring is fitted correctly, the dimension -X- is at least
15 mm. If this dimension is not reached, the Seger ring must be fitted
again. If necessary, carefully press the wheel bearing again.
5. Position the → see figure wheel hub in the correct position. Position
the T10205/10 pressure piece (from attachments T10205 ) in the
correct position on the wheel hub. Insert the tubular piston cylinder
VAS 6178. Position the T10205/6 pressure disc (from attachments
T10205 ) and the T10205/8-2 threaded nut (from attachments
T10205 ) in the correct position. Pull in the wheel hub. Shortly before
the stop, the applied force will be between 6.5 ftlb. and 26 ftlb. The
maximum assembling force must not exceed 30 ftlb. at the stop.
Subsequent work
Subsequent work
1. Fit the drive shaft, brake shoes, brake disc, and brake caliper in reverse order. Engage the cable of the foot-
operated parking brake and adjust the brake shoes → 468316 Adjusting foot-operated parking brake -
chapter on "Adjusting".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
Note
Spring strut screws are under tension. Use a suitable lift with rubber
base.
1. Remove spring strut at wheel carrier. Let connecting rod hang to the
side.
Note
Tighten all four screws for spring strut attachment at top (damper housing top) to the specified tightening
torque! To do this, use an extension and a universal joint for the inner fastening screws!
Replace all expansion screws (screws which are fitted with torque
angle tightening procedure)!
1. Insert spring strut into vehicle. When doing this, tighten the rear inner fastening screws (from the damper
housing at top) with an extension and universal joint. Tighten all four screws to 60 Nm (44 ftlb.)!
2. Install lower spring strut attachment with connecting rod. While doing
so, use the transmission jack to install the fastening screw. Tighten
fastening screw to the correct tightening torque and torque angle! Do
not damage the brake cover plate.
Subsequent work
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Information
Component overview
Standard Cayenne Turbo equipment: Air springs with level regulation and vertical adjustment.
Steel spring strut, complete
Mounting instructions
ATTENTION
Increased risk of accidents due to spring tensioning.
Danger of injury and damage from springs jumping out.
Note
Observe the correct allocation (engine variant) when installing new coil springs and/or shock absorbers.
Observe allocation of the bottom spring plate according to the coil spring tolerance group.
1. Clamp spring strut on eye of vibration damper in the vice (use jaw liners).
2. Tension the coil springs -see Figure- using spring clamp for spring struts NR.121 until the piston rod is
relieved.
Removing/fitting spring-strut mount
Spring clamp
3. Loosen the connection (piston rod to spring-strut supporting mount) at the piston rod using a commercially
available changeover ratchet and a socket wrench insert 3353. Counter with an arm bracket 9630.
The bottom support (spring plate) is allocated according to the coil spring tolerance group.
The colour coding -arrow- of the coil spring is located at the middle of the
coil spring and is indicated by coloured dots → Distinguishing feature and
allocation of coil springs and shock absorbers.
The shock absorbers are allocated using the spare part numbers and the model specification. At present, three
different shock absorbers are used on the rear axle of the Cayenne and Cayenne S. Refer to the Parts Catalogue
for the allocation.
1. Place the cap -1- , rubber stop -2- and protective sleeve -3- together
as follows before pushing them on to the piston rod:
– Push the rubber stop -2- up fully into the protective sleeve -3- .
– Insert the cap into the protective sleeve -see figure- and pull the lip carefully over the cap.
2. Place the bottom concave washer -see figure- together with the
bottom support -see figure- at the correct position (not twisted).
At the correct position means that the two individual parts are fitted
precisely together.
At the correct position means that the two individual parts are fitted
precisely together.
Assembly
ATTENTION
Increased risk of accidents due to spring tensioning.
Danger of injury and damage from springs jumping out.
1. Position the bottom support and bottom spring retainer assembly at the correct position on the shock
absorber.
6. Once the mount is positioned, fit the new lock nut. Screw the lock nut onto the piston rod until approx. 1 to 2
threads are visible above the lock nut. Then tighten with double-arm torque wrench 15 - 65 Nm (48 ftlb.)
NR.93.
7. Complete the following steps to ensure that the protective sleeve -see figure- is seated correctly:
– Push the protective sleeve -arrow- up fully and clip it into the concave support.
Fitting protective sleeve in top spring Concave support assembly
strut
– Push the protective sleeve -arrow- down fully and clip it to the shock
absorber with the cap (audible click).
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Danger of injury and risk of damage to property.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
2. Remove exhaust system → 260119 Removing and installing exhaust system - section on "Removing".
Removing stabiliser
Component overview - anti-roll bar → Component overview - anti-roll bar
Component overview - anti-roll bar
1- Anti-roll bar
2- Anti-roll-bar mount
3- Clamp
4- Fastening screws
5- Connecting rod
6- Fastening nut
7- Fastening screw
3. Mark the installation position -arrow- of the anti-roll-bar mount halves with respect to the anti-roll bar with a
paint marker.
Installing stabiliser
ATTENTION
Increased risk of accidents if the
wheel carrier is raised
improperly!
Danger of injury and risk of
damage to property.
Note
The entire threaded joints of the axle must be tightened in vehicle
position. Vehicle position means: vehicle standing on the wheels, or
the wheel suspension is raised with a universal vehicle lift. Dimension
-X- , from lower edge of wing to middle of axle 506 mm ±10 mm
corresponds to vehicle position.
Replace all expansion screws (screws which are fitted with torque angle tightening procedure).
1. Fit the → see figure anti-roll-bar halves at the previously applied marking on the anti-roll bar. The larger outer
diameter of the halves of the anti-roll-bar mount is on the wheel side.
3. Position anti-roll bar and fit clamps with the four fastening screws. Fit connecting rods to anti-roll bar.
4. Tighten the four anti-roll bar fastening screws.
Subsequent work
1. Fit exhaust system → 260119 Removing and installing exhaust system - section on "Installing" .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Connect the Porsche System Tester and in the menu select >> Offroad Stabi (ORS) >> Drive links >> Clock
valve VA or valve HA <<.
3. Remove the rear muffler → 260119 Removing and installing exhaust system - chapter on "removing".
WARNING
Risk of accidents! The Offroad Stabilizer System (ORS) operates at an overpressure of up to 165 bar.
Under certain conditions, motions can occur on the wheel carrier (e.g., if the Offroad stabilizers are
disengaged when lifting, the button is pressed on the centre console, and the wheel carrier is also
raised). The stabilizer can close quickly.
Danger of crushing in the area of the stabilizers and wheel
carriers. Injury and material damage due to raising the wheel
carrier incorrectly.
→ Before working on the vehicle, ensure that the ORS is engaged. The
indicator light on the centre console button must be OFF . If the
indicator light is on, follow the following procedure: Switch on the
ignition and engage the road driving programme >> High Range <<.
The stabilizers must audibly engage.
→ Before working on the ORS, depressurise the system!. To do this,
connect the Porsche System Tester and in the menu select >>
Offroad Stabi (ORS) >> Drive links >> Clock valve VA or valve HA
<<. The valve clocks (audibly) until the procedure is finished.
→ Do not raise the wheel suspension higher than the normal vehicle
position (vehicle resting on wheels). When raising the suspension,
use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
1. Release connecting link at stabilizer on left and right. To do this, use a suitable lift to raise the wheel carrier
sufficiently for the pin of the connecting link to be pulled easily out of the stabilizer. Use a suitable lift with
→ see figure rubber base in order to prevent slipping.
ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
Injury and material damage possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
Note
The entire threaded parts of the axle must be tightened in vehicle
position! Vehicle position means: vehicle standing on the wheels, or
the wheel suspension is being raised with a universal vehicle lift.
Dimension -X- , from lower edge of wing to middle of axle 506 mm ±
10 mm corresponds to vehicle position.
Replace all expansion screws (screws which are fitted with torque angle tightening procedure).
3. Insert stabilizer and fit clamps with the four fastening screws. Mount
connecting links at stabilizer.
5. Fit the lines -arrows- and the connector. Fit the lines -arrows- and counter with an open-ended wrench.
Connect the connector.
Subsequent work
1. Fit the rear muffler → 260119 Removing and installing exhaust system - chapter on "installing".
2. Bleed the Offroad Stabilizer System → 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter on
"bleeding".
9PAAD1, 9PAAD7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Technical values
Suspension subframe
Axle strut
Tie rod
1) Always replace screws and fastening nuts, which have to be tightened with torque angle, after being tightened.
2) Replace screws and fastening nuts whenever removed.
Spring strut
Damper housing
Anti-roll bar/suspension/stabiliser
Drive shaft
Wheel carrier
Differential
Wheel
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Note
As of a mileage of 200,000 Km it is recommended that the air springs be replaced per axle if there is damage to
one air spring.
If the shock absorbers leak, the complete air spring strut is to be replaced. The oil of the shock absorber can
damage the roller.
When depressurised, the air spring must not be twisted. There is the danger that the roller in the inside of the air
spring will be damaged by bending or folding and thus significantly reduce the running time.
Air-spring strut
1. Before loosening the air lines in the installed state, check if the rolling
boot is still filled with the residual pressure of approx. 3 bar. To do
this, press on the rolling boot of the air spring with your thumb. The
rolling boot must give perceptible resistance. If no significant
resistance can be felt, the air spring is depressurised and must be
replaced along with the residual pressure retaining valve.
The greatest possible care and cleanliness, as well as perfect tools are
important requirements for carrying out perfect repairs on air-spring struts.
The general and basic rules of safety apply. These are specifically listed
here again for repairing air-spring struts.
– Do not take spare parts out of the packaging until right before installation.
– Carefully cover open components or close them if the repair work will not be carried out immediately.
ATTENTION
Lowering of the vehicle when loosening the air line. The residual pressure retaining valve can become
loose when loosening the air line.
The vehicle lowers on the side on which the line/the residual pressure retaining valve is loosened.
Risk of squashing.
→ When loosening the residual pressure retaining valve, lift the vehicle on a platform lift.
→ Only leave the vehicle on the platform lift until a new residual pressure retaining valve is installed and the
air-spring strut is filled.
– it does not allow any more air to come out (valve jammed).
If the residual pressure retaining valve is jammed, the vehicle must be lifted for replacement on the platform lift
and the wheels must be allowed to turn freely. It must not be compressed with an empty rolling boot.
After removing gaskets, examine the contact surfaces on housings for burrs and damage.
Always loosen and tighten screws or nuts in diagonally opposite sequence for mounting covers and housing.
Information
Always replace the complete air spring -7- (figure shows component arrangement of front air-spring strut)!
1 - Sealing ring
2 - Lid
3 - Outer guide
4 - Rolling boot
5 - Rolling piston
6 - Bellows
7 - Shock absorber
8 - Sealing ring
1- Hexagon-head bolt
2- Mounting saddle
3- Hexagon nut
4- Spring-strut mount
5- Sealing ring
6- Residual pressure retaining valve
7- Air spring
8- Rubber stop
9- Shock absorber
10 - Sealing ring
11 - Boot/bellows
12 - Clamp
ATTENTION
The air-spring strut is pressurised with approx. 3 bar residual pressure. Never us an impact bolter to
loosen the fastening screws. Do not bend over the mounting saddle during disassembly.
Risk of injury from the pressurised air-spring strut when loosening the screws.
→ Always unscrew the screws on the mounting saddle by one turn only, on alternating sides. During
disassembly, allow the air to escape by tilting the mounting saddle slightly.
Note
When replacing the air spring, always replace the boot/bellows.
If the rolling piston slips out of the outer guide during disassembly, it must
be correctly positioned again when assembling.
When sliding in the rolling piston, the roller must lie evenly between
the outer guide and rolling piston (roll fold).
7. Remove boot/bellows.
Rubber stop
8. When replacing the shock absorber, remove the wheel acceleration
sensor -1- and fit it on the new shock absorber.
Note
When replacing the air spring, always replace the boot/bellows.
If the rolling piston slips out of the outer guide during disassembly, it must be correctly positioned again.
When sliding in the rolling piston, the roller must lie evenly between the outer guide and rolling piston (roll
fold).
If the shock absorber is not replaced, the sealing ring must be replaced.
Make sure that everything remains absolutely clean. The smallest impurities can cause leakages.
Clean the contact surfaces of the sealing rings with a lint-free cloth.
Lightly grease sealing rings with Syntheso Glep 1 (ET No. 000.043.204.68).
Roll fold
5. Clean the surfaces -2- on the mounting saddle and on the air spring with a lint-free cloth. Replace sealing
ring -1- on the air spring.
Note
To align the air spring, carefully
turn the rolling piston in order to
not damage the roller.
3. If air bubbles appear in the water bath, the air-spring strut must be
disassembled again. Replace all sealing rings again. Check the
residual pressure retaining valve again visually.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Note
As of a mileage of 200,000 Km it is recommended that the air springs be replaced per axle if there is damage to
one air spring.
If the shock absorbers leak, the complete air spring strut is to be replaced. The oil of the shock absorber can
damage the roller.
When depressurised, the air spring must not be twisted. There is the danger that the roller in the inside of the air
spring will be damaged by bending or folding and thus significantly reduce the running time.
Air-spring strut
1. Before loosening the air lines in the installed state, check if the rolling
boot is still filled with the residual pressure of approx. 3 bar. To do
this, press on the rolling boot of the air spring with your thumb. The
rolling boot must give perceptible resistance. If no significant
resistance can be felt, the air spring is depressurised and must be
replaced along with the residual pressure retaining valve.
The greatest possible care and cleanliness, as well as perfect tools are
important requirements for carrying out perfect repairs on air-spring struts.
The general and basic rules of safety apply. These are specifically listed
here again for repairing air-spring struts.
– Do not take spare parts out of the packaging until right before installation.
– Carefully cover open components or close them if the repair work will not be carried out immediately.
After removing gaskets, examine the contact surfaces on housings for burrs and damage.
Always loosen and tighten screws or nuts crosswise for mounting covers and housing.
→ When loosening the residual pressure retaining valve, lift the vehicle on a platform lift.
→ Only leave the vehicle on the platform lift until a new residual pressure retaining valve is installed and the
air-spring strut is filled.
– it does not allow any more air to come out (valve jammed).
If the residual pressure retaining valve is jammed, the vehicle must be lifted for replacement on the platform lift
and the wheels must be allowed to turn freely. It must not be compressed with an empty rolling boot.
Information
Overview of rear air-spring strut
Note
The components of the air spring -7- (figure shows component arrangement of rear air-spring strut), Items
-2; 3; 4; 5- (figure shows rear air-spring strut), cannot be disassembled.
Always replace the complete air spring -7- (figure shows component arrangement of rear air-spring strut)!
1 - Sealing ring
2 - Lid
3 - Outer guide
4 - Rolling boot
5 - Rolling piston
6 - Bellows
7 - Shock absorber
8 - Sealing ring
1- Hexagon-head bolt
2- Mounting saddle
3- Hexagon nut
4- Spring-strut mount
5- Sealing ring
6- Residual pressure retaining valve
7- Air spring
8- Rubber stop
9- Hexagon nut
10 - Protective cap
11 - Shock absorber
12 - Sealing ring
13 - Boot/bellows
14 - Clamp
ATTENTION
The air-spring strut is pressurised with approx. 3 bar residual pressure. Never us an impact bolter to
loosen the fastening screws. Do not bend over the mounting saddle during disassembly.
Risk of injury from the pressurised air-spring strut when loosening the screws.
→ Always unscrew the screws on the mounting saddle by one turn only, on alternating sides. During
disassembly, allow the air to escape by tilting the mounting saddle slightly.
Note
When replacing the air spring, always replace the boot/bellows.
If the rolling piston slips out of the outer guide during disassembly, it must
be correctly positioned again when assembling.
When sliding in the rolling piston, the roller must lie evenly between
the outer guide and rolling piston (roll fold).
8. Remove boot/bellows.
9. When replacing the shock absorber, remove the cap and fit it on the
new shock absorber.
Rubber stop
Assembling spring strut
Note
When replacing the air spring, always replace the boot/bellows.
If the rolling piston slips out of the outer guide during disassembly, it must be correctly positioned again.
When sliding in the rolling piston, the roller must lie evenly between the outer guide and rolling piston (roll
fold).
If the shock absorber is not replaced, the sealing ring must be replaced.
Make sure that everything remains absolutely clean. The smallest impurities can cause leakages.
Clean the contact surfaces of the sealing rings with a lint-free cloth.
Lightly grease sealing rings with Syntheso Glep 1 (ET No. 000.043.204.68).
Roll fold
5. Clean the surfaces -2- on the mounting saddle and on the air spring with a lint-free cloth. Replace sealing
ring -1- on the air spring.
6. Align the air spring so that the residual pressure retaining valve is located close to the imaginary axis of
Sealing ring
8. Fit spring-strut mount with socket wrench insert 3353 and arm
bracket P9630.
2. There must be no air bubbles rising in the water bath. If no air bubbles can be seen, the air-spring strut can
be fitted in the vehicle.
3. If air bubbles appear in the water bath, the air-spring strut must be disassembled again. Replace all sealing
rings again. Check the residual pressure retaining valve again visually.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
The air-spring struts are pre-filled to approx. 3 bar overpressure ex-works. If a new air-spring strut is installed, air
can diffuse (escape) from the bellows of the air-spring strut as a result of storage times of varying duration. If the
air-spring strut is removed from the transport packaging and installed without being filled, the bellows can fall into
folds, thereby damaging the air-spring strut. For this reason, all air-spring struts must be re-filled prior to use! The
procedure is described in detail in the course of the repair instructions.
ATTENTION
Increased risk of accident due to compressed gas bottles under high pressure (up to 200 bar).
Injuries and material damage are possible.
→ Observe the relevant operating regulations for handling compressed air and gas filling units.
→ Observe accident prevention regulations.
Note
Do not remove air-spring strut from transport packaging until it has been filled. This will prevent damage to
the inner bellows.
The air-spring strut must be screwed securely in the transport packaging during filling.
During assembly work, make sure that there are no pressure marks on the protective boot of the air-spring
strut.
After installation, first set the high level, then go to normal level. Repeat this procedure once more. This
procedure replaces most of the gas with the cleaned air from the air supply unit.
2. Pull off protective cap on residual pressure retaining valve. Carefully remove any left-over packaging.
3. Pull off plug connection on residual pressure retaining valve (a/f 12)
and screw on the filling unit adapter T10157/1 at the correct position
on the residual pressure retaining valve.
Note
The air-spring strut must only be filled with the approved gasses,
dual-process gasses Argon and Corgon.
Fill the air-spring strut using several individual pressure shots. Filling
the air with individual pressure shots will prevent the air-spring strut
from being filled with too much overpressure.
Do not fill the air-spring strut with overpressure of more than 4.5 bar.
The residual pressure retaining valve automatically reduces excessive overpressure to the minimum
overpressure of approx. 3 bar.
4. Fit the → see figure filling unit to the pressure gauge unit of the compressed air bottle.
5. Set the → see figure pressure gauge unit (flow limiter) to approx. 20 l/min -arrow- .
6. Overcome the counter-pressure of the residual pressure retaining valve with several individual pressure
shots and fill the air-spring strut. When sufficient air has been filled, between 2.5 and 4.5 bar -arrows- , pull
off the connection from the residual pressure retaining valve. Do not exceed the maximum value of 4.5 bar.
7. Once the air-spring strut has been filled correctly, it can be removed from the transport packaging and fitted.
9PAAD1, 9PAAD7, 9PAAE1,
9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
ATTENTION
Residual air can escape when removing the air lines.
Clean the screw connection of the lines from the valve block before
removing.
Protect the screw connection of the lines from dirt with suitable plugs.
2. Remove the → see figure air lines (colour-coded) from the valve unit
and the brown air line (running under the valve unit).
3. Release the mounting points on the body -A, B & C- and remove the
compressor unit (compressor, valve block).
Note
Install in reverse order.
Pay attention to cleanliness, if necessary clean the screw connections of the air lines with a lint-free cloth.
To fill the level adjustment system, use the Porsche System Tester. To do this, in the system >> Level
adjustment >> select the menu item >> Fill <<; then fill the front and rear axles and the accumulator. Switch
on level adjustment → 40 Lifting the vehicle(see Switching on level adjustment).
1. Fit compressor on the support, clip in the line, and fasten the cable.
2. Insert compressor unit and mount on the body -(A, B & C)- .
3. Fit the → Air lines for valve block air lines to the valve block.
-1- - black
-2- - lilac
-3- - blue
-4- - green
-5- - red
-6- - yellow
-7- - brown
Subsequent work
Fit right cover → 519319 Removing and installing centre cover - chapter on "installing" .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
WARNING
Risk of damage to electronic control modules.
If care is not taken, electrical and electronic components may be destroyed.
→ Before removing the control module, switch off the ignition and remove the ignition key.
Note
The control module is located behind the right rear side section trim.
Installation Location:
3. Pull up the clip of the control module holder and tilt the control module out of the holder.
4. Pull the latch of the upper electrical plug upwards -a- and remove plug.
Pull plug off at the bottom of the level
control module.
5. Pull out control module and pull the latch on the electrical plug -a- and remove plug.
1. First place the smaller plug on the control module and slide in the
latch -a- .
3. Code level control module. → 431619 Removing and installing level control system control module -
"Coding" chapter
4. Calibrate the level control module → 431619 Removing and installing level control system control module -
"Calibrating" chapter
5. Insert the control module into the holder and position with the clip.
6. Store the emergency kit and warning triangle and place on the cover of the right rear side section trim.
Push plug on at the top of the level
control module.
Note
During coding, it is essential to guarantee the power supply for the PIWIS Tester 9718. It is essential to
connect a battery charger with a current rating of at least 40 A to the vehicle battery.
The PIWIS Tester 9718 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 PIWIS tester 9718.
1. Connect the PIWIS tester 9718 to the vehicle and start it. Switch on the ignition. >> Continue.
3. Using the >> key, move from the vehicle type to the list of control modules.
Select country
Cayenne RoW
Cayenne Thailand
7. Read out fault memory and erase if required.
Note
During coding, it is essential to guarantee the power supply for the PIWIS Tester 9718. It is essential to
connect a battery charger with a current rating of at least 40 A to the vehicle battery.
The PIWIS Tester 9718 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 PIWIS tester 9718.
1. Connect the PIWIS tester 9718 to the vehicle and start it. Switch on the ignition. >> Continue.
3. Using the >> key, move from the vehicle type to the list of control modules.
6. Select the Actual values menu and display the safety code. Then read out the safety code and make note
of it.
7. Select the menu Calibration, enter the safety code and carry out the Calibration function. Follow the
instructions on the PIWIS tester .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
In running gear with level adjustment, a self-levelling sensor is installed on each spring strut.
The self-levelling sensor is screwed to the bearing block and upper control arm.
1. Counter with an open-ended wrench on the two flats -1- and unscrew
the fastening nuts -2- .
2. Unscrew both fastening screws -3- .
3. Disengage lever from self-levelling sensor, swivel it forwards and remove the sensor.
1. Press the electric connector onto the self-levelling sensor until it clicks into place..
If a new self-levelling sensor is installed, then the control unit for level
adjustment must be calibrated.
Information, measuring points, procedure, and conditions for calibration: → 43 K2 Calibrating - chapter on
"calibrating"
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition.
5. Read out fault memory. If fault is present, proceed in accordance with Rep - Gr. 4316 Level adjustment
diagnosis.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
In running gear with level adjustment, a self-levelling sensor is
installed on each spring strut.
1. Counter with an open-ended wrench on the two flats -1- and unscrew
the fastening nuts.
If a new self-levelling sensor is installed, then the control unit for level
adjustment must be calibrated.
Information, measuring points, procedure, and conditions for calibration: → 43 K2 Calibrating - chapter on
"calibrating"
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition.
5. Read out fault memory. If fault is present, proceed in accordance with Rep - Gr. 4316 Level adjustment
diagnosis.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
ATTENTION
Increased risk of accidents due to raising the wheel carrier incorrectly.
Injury and material damage possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When
raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
The relevant wheel must be removed when carrying out repairs to avoid damaging the drive shaft.
Installation Location:
3. Loosen pressure line on residual pressure retaining valve -arrow- using insert part T10212 (front spring
strut connection in figure). Then, unclip the pressure line from the holders and set it aside.
5. Disconnect CDC sensor plug connection -arrow- , remove the cable from the holder, and set the cable
aside.
ATTENTION
Increased risk of accident due to raising the wheel carrier
incorrectly. When filling the air spring struts, the vehicle lifts.
Injury and material damage possible.
→ Do not raise the wheel suspension higher than the normal vehicle
position (vehicle resting on wheels). When raising the suspension,
use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
Note
Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When
raising the suspension, use a suitable intermediate layer (hard rubber).
Replace all expansion screws (screws which are fitted with torque angle tightening procedure)!
3. Carefully raise the air spring strut using a suitable -figure- lift with
rubber base. Then, pull the wheel carrier downwards in order to fit
the fastening screw.
4. Attach the fastening screw for the connecting link/spring strut -arrow-
to the wheel carrier.
5. Connect the CDC sensor plug connection to the lower part of the
spring strut -(arrow)- . Insert cable into the holders.
7. Fit pressure pipe to residual-pressure retaining valve using insert part T10212 → Tightening
torques [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Tightening torques [9PAAJ1]. Then clip the
pressure line into the retaining devices.
8. Remove protective tube from drive shaft.
Subsequent work
Subsequent work
1. Fit wheel → 440519 Removing and installing wheels - section on "Installing" .
2. To fill the air suspension (the system must be filled with compressed
air), use the -Porsche System Tester- . To do this, select the menu
item Fill air suspension in the Air suspension system.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1. Remove cowl panel → 664419 Removing and installing cowl panel - section on "Removing".
2. Remove the relevant engine compartment side cover → 700219 Removing and installing front cover (engine
compartment) - section on "Removing".
3. Remove hub cap using puller hook 9229 and undo drive shaft fastening at the side of the wheel before
raising the vehicle. Operate the brake whilst doing so (second fitter required).
The air springs are installed as standard in the Cayenne Turbo and are optional in the Cayenne S. The steel
springs are not applicable for the Cayenne Turbo.
ATTENTION
Increased risk of accident due to raising the wheel carrier incorrectly.
Injury and material damage possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When
raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
When fitting/removing the air spring strut, the drive shaft is removed and installed.
2. Lift wheel carrier carefully to facilitate removal. Use a suitable → see figure lift with rubber base in order to
prevent slipping.
3. Loosen pressure line at the residual pressure retaining valve -arrow- using insert part T10212.
4. Separate compact connector (in wheel housing on side member) -arrow- and the plug connections for the
wheel acceleration sensor and self-levelling sensor.
5. Remove lower connecting link -arrow- using the lift to support the wheel carrier (assembly aid).
6. Unscrew plastic nuts -arrows-
on wheel housing liner.
9. Slide protective tube (shop made) 00000 over drive shaft. Release
drive shaft at transmission flange and lay down carefully. Use a
suitable base for the front axle carrier.
11. Remove the two holders (brake hose, combination line) on wheel
carrier and let them hang.
12. Disconnect ABS sensor plug connection.
13. Remove the relevant outer -figure- tie rod joint using the press-out
tool T10187. When pressing out, screw fastening nut on flush (this
protects the ball joint thread).
14. Press out → see figure ball joint of upper trailing arm from wheel carrier using press-out tool T10187.
15. Remove the spring compressor VW 552.
16. Remove brake calliper fastening screws and hang -figure- brake calliper in a suitable place in the wheel
housing.
17. Remove drive shaft. To do this, the first fitter must carefully pull the top of the wheel carrier outwards and the
second fitter must carefully guide out the drive shaft.
18. Remove the three mounts for the spring strut in the engine compartment (two mounting points in front of
plenum panel and one inside the plenum panel). The three mounting points -(arrow)- are shown here from
inside the wheel housing (wheel carrier installed).
19. Carefully guide out the spring
strut.
ATTENTION
Increased risk of accident due to raising the wheel carrier
incorrectly. When filling the air spring struts, the vehicle lifts.
Injury and material damage possible.
→ Do not raise the wheel suspension higher than the normal vehicle
position (vehicle resting on wheels). When raising the suspension,
use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
Note
Visually inspect all parts.
If a new spring strut is fitted, it must be pre-filled to 3 bar in its original packaging → Filling specification for
air-spring strut.
Replace all expansion screws (screws which are fitted with torque angle tightening procedure).
When fitting the ball joints, ensure that the bevel pinions are clean!
Remove dirt or grease on bevel pinions, e.g. with a lint-free cloth. Do
not use cleaning agent/solvent.
1. Carefully guide in spring strut -arrow- , position with the auxiliary pins
and tighten at the mounting saddle with the specified tightening
torque → Tightening torques for front axle.
2. Fit drive shaft. To do this, first fitter must carefully pull the top of the wheel carrier outwards and the second
fitter must carefully guide in the drive shaft.
3. Fit brake calliper on wheel carrier (do not tighten brake calliper fastening screws yet).
4. Mount wheel carrier on upper trailing arm. When doing this, observe
drive shaft clearance (use suitable base). To facilitate assembly and
avoid the upper ball pin falling into the stop, raise the wheel carrier
slightly with a suitable lift so that the upper ball pin can be inserted.
Use a → see figure lift with rubber base in order to prevent slipping.
5. Insert spring compressor VW 552 and slightly tension upper trailing
arm.
6. Fit fastening bolt for lower spring strut. Remove spring compressor
VW 552 tension jack.
11. Fit pressure line at residual pressure retaining valve -(arrow)- using
insert part T10212. Note tightening torque. → Tightening torques for
front axle
12. Mount ball joint of tie rod on wheel carrier. → see figure Tighten lock
nut to specified tightening torque → Tightening torques for front axle.
Subsequent work
Subsequent work
1. Fit wheel → 440519 Removing and installing wheels - section on "Installing" .
2. Tighten axle nuts → Tightening torques for front axle. Operate the brake whilst doing so (second fitter
required).
3. Fit the relevant engine compartment side cover → 700219 Removing and installing front cover (engine
compartment) - section on "Removing".
4. Fit cowl panel → 664419 Removing and installing cowl panel - section on "Removing".
5. To fill the level adjustment system, use the Porsche System Tester. To do this, select the Fill level
adjustment menu item in the Level adjustment system. Switch on level adjustment → Lifting the
vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1].
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Note
These instructions for removal and installation describe all the sensors for the body (two sensors at the front, one
sensor at the rear).
Installation position at front: Position 8, under the left and right wings.
Installation position at rear: Position 8, under the boot floor plate on the right (sensor can be accessed from the
interior!).
Front sensor
2. Remove wheel housing liner. → 505619 Removing and installing front wheel housing liner
Rear sensor
Note
For removing and installing the rear sensor, it is not necessary to lift the vehicle.
1. Remove boot floor plate (centre part) and remove only the right side cover. → 700619 Installing and
removing luggage compartment trim (loadspace cover)
Removal
Removing
Front sensor
Rear sensor
Installing
Installing
Front sensor
1. Insert sensor with holder in the correct position -arrow- and tighten the fastening screw.
2. Plug in connector. Pay attention to correct line routing.
Rear sensor
1. Insert sensor with holder in the correct position -arrow- and tighten the fastening nut.
Subsequent work
Front sensor
1. Install wheel housing liner. → 505619 Removing and installing front wheel housing liner
Rear sensor
2. Fit right side cover and install the boot floor plate (centre part). → 700619 Installing and removing luggage
compartment trim (loadspace cover)
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Using a plug connection (see Spare Parts Catalogue), individual sections of pressure hoses can be safely
joined again.
The pressure hoses are correctly fitted when the first colour marking
(self applied) is no longer visible and the second colour marking is
still visible.
The following points must be observed when choosing the repair point:
– The repair point must lie in an area protected from water spray
– Insert the ends of the pressure hoses firmly into the push-on connector.
Repair
Note
When filling the air suspension, the vehicle lifts.
3. When repairing the pressure hose, cut off the damaged section squarely using the cutters cutters VAS 6228
00000.
4. Mark the pressure hose to be replaced in colour (e.g. with a waterproof marker). Measured from the cut-off
end of the hose, make two coloured marks at 16 mm and 22 mm respectively -(arrows)- .
5. Insert the pipe until the range between the two colour markings min. 16 mm up to max. 22 mm -(arrows)-
has been reached.
To fill the air system, use the Porsche System Tester. To do this, select the menu item Fill air suspension in the
Air suspension system. Switch on level adjustment → 40 Lifting the vehicle.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
The air suspension with level adjustment makes it possible to actively adapt the ground clearance of the Cayenne
to the situation in which the vehicle is being used or to its load. More ground clearance off-road by manual
adjustment to off-road level or automatic lowering at high speed.
Depending on the load, by increasing or decreasing the air volume it is possible to achieve various vehicle heights
with different suspension characteristics. The amount of air needed for each air spring strut is determined by
means of a control unit and provided via an air supply consisting of compressor, a solenoid block and two
accumulators.
Wheel acceleration sensors -9- are no longer fitted as of January 2004. Precise data and scopes can be found in
the spares catalogue. If the air-spring struts have to be replaced, the wheel acceleration sensors (for vehicles
before January 2004) will need to be installed on the new air-spring struts.
No. Description of component Number Location
-1- Air spring strut, front axle 2 Wheel
housing/lower
control arm
-2- Air-spring strut, rear axle 2 Damper housing
(cross
member)/wheel
bearing housing
-3- Compressor 1 Underbody right
-4- Valve block 1 Underbody right
-5- Front accumulator, 5.21 litres 1 Underbody left
-6- Rear accumulator 4.87 litres 1 Boot floor plate
-7- Air suspension control unit 1 Luggage
compartment
right
-8- Body acceleration sensors ( 2x front and 1x rear) 3 Front wheel
housing
(right/left), boot
floor plate right
-9- Wheel acceleration sensors 2 Spring strut front
-10- Self-levelling sensors, front axle 2 Control arm
upper
-11- Self-levelling sensors, rear axle 2 Control arm
upper
-12- Compressed air connection 1 Under seat
frame front right
-13- Suction line for compressor 1 Connection to
air cleaner
housing
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
43 K2 Calibration - as of MY 2003
- Calibration
Calibration
Calibration must be carried out if control unit and/or self-levelling sensors are replaced. When doing this, the self-
levelling sensors are calibrated by determining a correction value (corresponding to the actual height of vehicle)
and permanently storing it in the control unit.
Notes on calibration
Note
Prior to calibration, the normal level must be adjusted! → 43 Calibration (Conditions for carrying out
calibration)
Ensure that tyre pressures have been adjusted to the respective tyre specifications. → 43 Calibration
(Wheels and tyres)
The security code is displayed in the Porsche System Tester under menu >> Level adjustment >> Actual
values.
The nominal values for the nominal heights of the level sensors are stored in the control unit. The actual values of
the respective axle heights, front left, front right, rear left, rear right, have to be measured manually and then
entered with the Porsche System Tester. The actual values are to be measured on the two axle supports (front
axle, rear axle), both on the right and left. → 43 Calibration (conditions for carrying out calibration)
The distance (middle of wheel) between the road (wheel contact area on measuring platform) and the measuring
point -A- on the axle support is measured.
The car is to be adjusted to normal level. → 43 Calibration (Adjusting car to normal level)
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.
Connect the Porsche System Tester. Select the test step Calibration in the Air suspension/level adjustment
system.
When calibrating, the vehicle moves down first and then moves up to normal level.
After normal level has been reached, determine the actual values of axle heights at measuring points.
If an implausible value is entered (actual value is not accepted), measure height again and enter value.
Tap the right-hand rocker switch on the centre console in the appropriate direction until vehicle has reached
normal level. The middle indicator light next to the rocker switch is permanently on. If a further indicator light
should come on, a different level is set.
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tightening torques
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Raise vehicle → 40 Lifting the vehicle.
Installation Location:
1. At the front, turn the steering so far that the speed sensor is made more easily accessible. The wheel in the
rear does not need to be removed.
2. Disconnect speed sensor connector.
Note
The speed sensor must be inserted using Optitemp (Optitemp LG2, 25-ml spray can available under Part No.
000.043.204.21).
The bore for mounting the speed sensor must be free of dirt.
2. Plug in connector.
Subsequent work
Lower vehicle → 40 Lifting the vehicle.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1. Remove plenum panel cover. → 664419 Removing and reinstalling cowl panel cover - chapter on
"Removing"
2. Using the bonnet stay 97040 the bonnet can be opened wider for better accessibility of the plenum panel.
To do this, remove the front gas spring and mount the bonnet stay. → 553119 Removing and reinstalling
front gas spring - chapter on "Removing"
3. Remove the DME control module -arrows- . → 247019 Removing and reinstalling DME control module-
chapter on "Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 247019 21 Removing and
reinstalling DME control module- chapter on "Removing" [9PAAJ1]
The brake lines must not be bent in the area of the hydraulic unit.
Clean the interfacing points of the brake lines, but not with cleaning agents.
The → see figure hydraulic unit is installed in the plenum panel on the front right, under the DME control unit.
Note
When fitting the hydraulic connections, the electric plug connections
on the control units must remain connected as long as possible. This
prevents the plug connections on the hydraulic unit or in the
connectors inside from being splashed with brake fluid or water.
The brake lines must not be bent in the area of the hydraulic unit.
Clean the interfacing points of the brake lines, but not with cleaning agents.
1. Release the ground cable -arrow- , unclip the wiring harness and set it aside.
3. Remove the housing of the intake air duct. To do so, loosen the two
external fastening nuts and the two retaining clips in the inside of the
air duct.
5. Activate the brake pedal by hand using the brake pedal loader, (do
not clamp it yet!). Plug the vent hose of the vent bottle onto the front
left and rear left bleeder screw of the brake calliper (2nd fitter
required). Open the bleeder screws until the brake pedal is
completely pressed down. Tighten the brake pedal loader and close
the bleeder screws. This will close the central valves of the tandem
brake master cylinder so that only a little brake fluid can flow out of
the opened brake system.
6. A sufficient number of cloths should be put under the hydraulic unit to absorb any brake fluid emerging. If
some runs into the plenum panel nonetheless, immediately rinse thoroughly with water.
7. Mark the → see figure lines on the hydraulic unit (colour marking,
etc.) and remove. Seal the loosened lines with suitable plugs.
8. Pull off the control unit connector from the control unit.
9. Remove the hydraulic unit (a/f 8) and take out of the bracket,
upwards.
DANGER
Porsche Stability Management does not work without values for the current brake pressure.
Danger of personal injury and material damage when the hydraulic unit is not calibrated.
→ After assembling the hydraulic unit, a static test and a swap test must be carried out with the Porsche
System Tester.
→ After assembly of the brake master cylinder or the hydraulic unit, the pressure sensor must be calibrated
with the Porsche System Tester.
Note
When fitting the hydraulic connections, the electric plug connections on the control units must remain
connected as long as possible. This prevents the plug connections on the hydraulic unit or in the connectors
inside from being splashed with brake fluid or water.
Any damp connector must be wiped dry before being disconnected from the connector on the hydraulic unit.
If necessary, provide the connector with a suitable protector.
Brake fluid on electrical contacts (even thinned brake fluid) leads to corrosion and may cause faults in the
system.
The brake lines must not be bent in the area of the hydraulic unit.
Clean the interfacing points of the brake lines, but not with cleaning agents.
Note
Install in reverse order.
Remove the plugs on the new hydraulic unit after the respective brake line is fitted.
1. Bleed the brake system . To ensure the full function of the brake system, drain approx. 250 ccm brake fluid
from each wheel → 470107 Bleeding the brake system - see section on "Bleeding".
To do this, select menu >> PSM >> Function selection >> Coding << and the relevant country. Observe the
country coding!
6. Perform a function test. During the test drive, perform at least one ABS control operation, taking the road
conditions into consideration. Read out fault memory. There must not be any stored faults.
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
ATTENTION
Increased risk of accident whever power supply is interrupted. PSM does not function.
→ The steering-angle sensor must be initialised (taught) whenever the battery is disconnected.
Note
The steering-angle sensor is integrated into the steering column switch and records the movements of the
steering wheel (steering wheel angle) using light switches. The data is transmitted to the PSM control unit via
the CAN bus.
During initialisation, the steering-angle sensor learns its current position (straight-ahead position).
The steering-angle sensor must always be initialised if terminal 30 was interrupted (for example, battery
replacement, undervoltage, steering column switch disconnected, relevant fuse removed)!
Calibration must be performed when working on or carrying out subsequent work on the chassis. This is
described in detail in the next chapter → 456000 15 Initialising and calibrating steering-angle sensor - section
on "Calibrating".
The steering angle sensor is calibrated when first fitted and when any work has been carried out on steering
and chassis. Examples of this would be opening the steering wiring and alterations to toe and camber.
Calibration includes initialisation.
2. Start engine.
3. From the straight-ahead position, turn steering wheel approx. 20° to the left and 20° to the right (past straight-
ahead position).
4. Drive the vehicle straight ahead for at least one second at a speed of over 4 km/h (2.5 mph).
Following successful initialisation, the stored fault code is set to "Not present". The PSM indicator light in the
instrument cluster goes out.
ATTENTION
Increased risk of accident if the battery is disconnected after initialising and/or the relevant fuse is
removed. There must be no undervoltage during the process.
→ Every time the battery is disconnected, the relevant fuse removed or an undervoltage is present, the steering-
angle sensor must be initialised (taught).
Note
The steering-angle sensor must be recalibrated on the measuring platform following repairs to or work on the
chassis/steering or if the steering-angle sensor/steering column switch/hydraulic unit is replaced.
In order to be able to calibrate the steering angle sensor correctly, the vehicle must be on the measuring
platform, the wheel alignment values correct and the steering in the straight-ahead position.
The security code is displayed in thePIWIS tester under Menu >> PSM >> Actual values.
The steering angle sensor must be calibrated using the menu with the Porsche System Tester under the specified
test conditions:
1. Switch on ignition.
4. In the straight-ahead position, the steering wheel must deviate by no more than ± 2.0° from the horizontal
position (steering centre position).
5. After successful calibration, the stored fault code is erased from the fault memory. The PSM indicator light in
the instrument cluster goes out.
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
General information
The steering-angle sensor is integrated into the → see figure steering column switch.
The steering angle is recorded in the contact unit for airbags (spiral spring) -C- . The sensed data is sent from the
electronic unit -E- via the drive CAN bus to various systems (e.g., PSM, corner-sensitive headlight) for further
processing. Replacement of the steering angle sensor requires the steering column switch to be removed.
If faults have been diagnosed on the steering-angle sensor, the steering column switch must be disassembled
into the components -A, B, C, D, E- .
It is only permissible to replace the steering-angle sensor as the combination of the components contact unit for
airbag -C- (spiral spring) and electronic unit -E- .
A- Direction indicator switch
B- GRA switch
C- Contact unit for airbag (spiral spring)
D- Switch for wiper and washer system
E- Electronic unit
1. In order to replace the steering angle sensor, the components contact unit for airbag -C- and the electronic
unit -E- must be replaced → 945019 Removing and installing steering column switch (Removing and
installing steering column switch includes disassembling and assembling).
2. Once installed, the steering angle sensor must be calibrated with the Porsche System Tester PSM
→ 456015 Initialising and calibrating steering-angle sensor.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
The functions listed below are integrated into the combination sensor:
Rate-of-turn sensor
Installation Location:
Overview of combination sensor
Warning notes
ATTENTION
Increased risk of accident if combination sensor is uncalibrated or incorrectly calibrated.
Possible danger of damage or injury.
→ After installation or replacement of combination sensor, calibrate vehicle with the Piwis tester.
→ Calibration must only be performed with the vehicle >> standing horizontally with the brakes off <<.
Subsequent work
Subsequent work
1. Install triggering unit for airbag. → 695319 Removing and installing triggering unit for airbag
2. Install centre console cover. → 681919 Removing and installing cover for centre console [9PAAD1 9PAAE1
9PAAF1 9PAAJ1]→ 681919 Removing and installing cover for centre console [9PAAD7 9PAAE7]
Note
After installation or replacement of combination sensor, calibrate vehicle.
Calibration must only be performed with the vehicle >> standing horizontally with the brakes off <<.
4. Calibrate combination sensor. To do this connect the Piwis tester: Select >> Vehicle Cayenne >> System
PSM >> Actual values menu >> Security code << (at end of list). Note the security code. Quit >> Actual
values menu << .
5. Select >> Calibration menu << . Enter security code. Calibrate >> Lateral acceleration sensor << and >>
Axial acceleration sensor << in sequence using the menu.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information on PSM
PSM is an active control system to stabilise the vehicle at the limit of driving dynamics. Sensors continuously
determine:
Vehicle speed
Direction of travel (steering angle)
Transverse acceleration
Longitudinal acceleration
Rate of turn
Note
The PSM (Porsche Stability Management) is automatically ready/switched on after each engine start.
Off-road PSM
When the Low Range/Off-road programme is switched on, an off-road PSM specially adapted for off-road terrain
to improve traction is automatically activated. At speeds below 35 km/h, the off-road PSM reacts later in the case
of under or oversteering and improves the steering control.
Press the PSM switch. The PSM switches off after a short delay.
When the PSM is off, the PSM OFF warning light in the instrument panel and the indicator light in the switch are
lit.
When braking, the vehicle is also stabilised when the PSM is switched off!
One-sided wheel spin is also prevented when the PSM is switched off!
On Tiptronic vehicles, the slip upshift function is switched off when PSM is switched off → 45 IN Information
on PSM - chapter on "Information"! Characteristic features of Tiptronic vehicles (slip upshift).
– On extremely difficult terrain (if one or more wheels have little or no road grip - engine performance is
reduced)
Press the PSM switch. The PSM switches on after a short delay.
When a maximum permissible speed difference between front and rear axle is exceeded, the integrated slip
monitoring shifts into the next highest gear. This increases the driving stability on slippery roads.
When PSM is switched off, the slip monitoring (slip upshift function) is also switched off. In this way, the
Tiptronic enables an active sporty driving style even when the friction coefficient is low as is the case with
manual transmission vehicles.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1. Move the driver's seat back.
2. Remove the lower cover. → 702219 Removing and installing cover under dashboard - chapter on
"removing" . At the diagnostic socket just unclip the connector from the rear.
Note
For better accessibility, remove the lower cover under the steering column.
Installation Location:
3. Remove the holder for the stop light switch and unclip the connector
-arrow- → 943619 Removing and installing stop light switch - chapter
on "removing".
5. Remove relay carrier -arrows- → 979019 Removing and installing relay carrier, plenum panel E-box - chapter
on "removing".
6. Remove both control units -arrow- , on the right side under the dashboard → 966619 Removing and installing
Kessy/immobilizer control unit - chapter on "removing", → 971019 Removing and installing vehicle electrical
system control unit - chapter on "removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 971019
21 Removing and installing vehicle electrical system control unit - chapter on "removing" [9PAAJ1].
7. Release the support (relay carrier/Kessy control unit/immobilizer/vehicle electrical system control unit) (left
side and front engaged, right side screwed) and let them hang. In this way, the brake pedal shaft can be
pushed out toward the centre of the vehicle (cardan tunnel).
8. Disengage the brake pushrod from the brake pedal mounting using
the unlocking tool T10189 . Observe the following procedure for this
purpose:
-1- - unlocking tool T10189 for brake pedal.
– Position the unlocking tool T10189 -1- so that the fork sits in correct position in the brake pedal mounting (in
the inset, the fork in contact, view against the direction of travel).
– When pressing forward on the lever (unlocking tool) (in direction of travel!), the brake pedal mounting is
pressed apart and the ball of the pushrod is released. At the same time, pull the brake pedal to the rear
(against the direction of travel!) and release the brake pedal from the pushrod.
9. Counter the brake pedal shaft (pin) -arrows- on the right side and slightly loosen to the left -(arrows)- . The
nut remains on the brake pedal shaft to protect the thread.
10. Loosen the two upward running struts of the articulated strut and let them hang. To do this, remove the
retainer on each retaining pin, remove the retaining pins, and let the struts hang down.
11. Using a hammer, force out the brake pedal shaft a few millimetres with short, heavy blows from left to right.
Brake pedal released from the
pushrod
12. Place a screwdriver under the head of the brake pedal shaft (right side). Remove the nut, and lever out the
brake pedal shaft carefully toward the centre of the vehicle (cardan tunnel).
13. Carefully press out the brake pedal shaft so that the brake pedal can be removed.
Note
Do not grease or spray the brake pedal shaft (pin).
For vehicles with automatic transmission a spacer tube is used instead of the clutch pedal.
Use new lock nuts.
Subsequent work
Remove the lower cover → 702219 Removing and installing cover under dashboard - chapter on "installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Technical values
Technical data for 18" brake system (4.5-litre and 4.5-litre twin-turbo)
Technical data, wear limits for Cayenne 17" brake system (3.2-litre)
Technical data on wear limits for 18" brake system (4.5-litre and 4.5-litre twin-turbo)
Technical data on wear limits for 19" brake system (4.5-litre twin-turbo) KIT
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Adjusting
Note
The brake pushrod play is strictly specified.
The brake pushrod can be removed from the brake pedal with the unlocking tool T10189 .
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Checking
WARNING
Risk of accident if brake pads and brake discs are not replaced in time.
Injury and material damage due to impaired braking effect.
→ The brake pads must be replaced when the brake pad warning indicator lights up, but no later than when
there is a residual pad thickness of 2 mm.
→ Brake discs must be replaced on reaching the wear limits.
Note
If brake pad wear is indicated by the warning light, the warning contact (sensor including line and plug
connection) must also be replaced.
Replacement of the warning contact can be avoided by replacing the brake pads no later than when the pad
thickness is 2.5 mm -arrows- .
However, if only the plastic part of the warning contact is worn, there is no need to replace it.
ATTENTION
Increased risk of accident or damage to brake discs when mounting/removing wheels.
Material damage to the brake discs.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Component arrangement
A foot-operated parking brake is used in the Porsche Cayenne.
Special demands for a sporty, multi-purpose vehicle have been taken into account when designing the foot-
operated parking brake. To achieve the required capabilities, it was designed as a foot-activated parking brake
with an intermediate transmission ratio. The Cayenne can be parked reliably with a full load on gradients of 55 %.
A cable is routed from the foot-operated lever to a deflection lever under the centre console which transmits
traction to a turnbuckle with a transmission ration of 3.1. Two cables are routed from the turnbuckle to the parking
brakes on the rear axle.
The foot-operated parking brake is designed as a duo-servo drum brake and is integrated into the rear brake
discs.
A - Parking brake release. Location: lower dashboard trim panel.
B - Parking brake pedal. Location: left side of driver's footwell.
C - Parking brake cable. Location: under carpet in driver's footwell.
D - Deflector. Location: under centre console.
E - Brake cable, rear. Location: Each fitted from the console/deflector to a rear wheel brake.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Special demands for a sporty, multi-purpose vehicle have been taken into account when designing the foot-
operated parking brake. To achieve the required capabilities, it was designed as a foot-activated parking brake
with an intermediate transmission ratio. The Cayenne can be parked reliably with a full load on gradients of 55 %.
A cable is routed from the foot-operated lever to a deflection lever under the centre console which transmits
traction to a turnbuckle with a transmission ration of 3.1. Two cables are routed from the turnbuckle to the parking
brakes on the rear axle.
The foot-operated parking brake is designed as a duo-servo drum brake and is integrated into the rear brake
discs.
-A- - Parking brake release. Arrangement: In the trim for lower dashboard.
-B- - Parking brake pedal. Arrangement: In left of driver's footwell.
-C- - Parking brake cable. Arrangement: Under carpet in driver's footwell.
-D- - Deflector. Arrangement: Under centre console.
-E- - Brake cable, rear. Arrangement: Fitted from the console/deflector to a rear wheel brake.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
Removing
If necessary, remove a little brake fluid from the expansion tank by suction to prevent overflow when the disc
brake pad is pushed back!
Installing
WARNING
Danger of accident if old parts are fitted on brake caliper.
Fit new expanding spring, new retaining pin and new retaining pin screw on the brake caliper.
→
WARNING
Danger of accident if brake pads of the wrong quality are installed.
Use only the type-specific brake pads in the Porsche Spare
Parts Catalogue.
Check disc brakes for wear; for wear limits see → 46 Technical
data/brake wear limits!
The core of the warning contact line must not be left exposed! Worn insulation is not significant!
1. If necessary, push brake piston back into its original position using the piston resetting fixture (replaces
P83) NR.144, see Workshop Equipment Manual, Chapter 2.4.
Note
Make sure that the retaining pin is inserted in the correct position! The flat side surfaces prevent the retaining
pin from twisting in the brake caliper.
3. Install expanding spring. Centre the retaining pin in the bore with the
M8 auxiliary screw. To do so, press retaining pin back with auxiliary
screw and push retaining pin through. Remove auxiliary screw and fit
fastening screw at retaining pin with specified tightening torque → 46
Tightening torques for brake mechanics!
4. Install warning contact line at disc brake pads and expanding spring -arrows- . The cable guide in the
expanding spring must be at the bottom!
5. Position disc brake pads by operating the brake several times.
6. Check brake fluid level and correct if necessary. The brake fluid level
must lie within the -MAX-MIN marking- .
Subsequent work
Subsequent work
1. Fit wheel → 440519 Removing and installing wheel - chapter on "installing" .
Information
New brake pads require a bedding-in period of approx. 200 km! Only then do they achieve their best friction and
wear coefficient! During this period, the brakes should only be subjected to full stress at high speed in
emergencies!
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove wheel. → 440519 Removing and installing wheel
WARNING
Danger of accident if brake pads of the wrong quality are installed.
This can result in longer braking distances and more wear.
→ Use only the type-specific brake pads in the Porsche Spare Parts Catalogue.
The core of the warning contact line must not be left exposed! Worn insulation is not significant!
If necessary, remove a little brake fluid from the expansion tank by suction to prevent overflow when the disc
brake pad is pushed back!
WARNING
Danger of accident if old parts are fitted on brake caliper.
This can cause malfunctions.
→ Fit new expanding spring, new retaining pin and new retaining pin
screw on the brake caliper.
Check disc brakes for wear. For wear limits see Technical Data → 46
TW Technical data/brake wear limits - chapter on "Technical values"!
The core of the warning contact line must not be left exposed! Worn
insulation is not significant!
Note
Make sure that the retaining pin is inserted in the correct position.
The flat side surfaces prevent the retaining pin from twisting in the
brake caliper.
3. Install expanding spring. Centre the retaining pin in the bore with the
M8 auxiliary screw. To do so, push retaining pin back with auxiliary
screw and push retaining pin through. Remove auxiliary screw and fit
fastening screw at retaining pin with specified tightening torque → 46
TW Tightening torques for brake mechanics - chapter on "Technical
values"!
4. Install warning contact line at disc brake pads and expanding spring -arrows- . The cable guide in the
expanding spring must be at the bottom!
6. Check brake fluid level and correct if necessary. The brake fluid level must lie within the → see figure MAX -
MIN marking.
New brake pads require a bedding-in period of approx. 200 km! Only then do they achieve their best friction and
wear coefficient! During this period, the brakes should only be subjected to full stress at high speed in
emergencies!
Subsequent work
Mount wheel. → 440519 Removing and installing wheel
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
Removing
If necessary, remove a little brake fluid from the expansion tank by suction to prevent overflow when the disc
brake pad is pushed back!
1. Remove lock (securing clip) -top arrow- from retaining pin and
remove retaining pin -direction arrow- inwards.
Installing
WARNING
Danger of accident if old parts are fitted on brake caliper.
Fit new expanding spring, new retaining pin and new safety bracket on the brake calliper.
→
WARNING
Danger of accident if brake pads of the wrong quality are installed.
Use only the type-specific brake pads in the Porsche Spare Parts Catalogue.
Note
The back of the pad backing plates must not be greased.
Check disc brakes for wear; for wear limits see → 46 Technical data/brake wear limits.
The core of the warning contact wire must not be left exposed! Worn insulation is not significant.
If necessary, remove a little brake fluid from the expansion tank by suction to prevent spilling when the disc
brake pad is pushed back.
1. If necessary, push brake piston back into its original position using the piston resetting fixture (replaces
P83) NR.144, see Workshop Equipment Manual, Chapter 2.4.
3. Fit expanding spring, retaining pin -direction arrow- and lock (safety
bracket) -top arrow- at top of retaining pin.
6. Check brake fluid level and correct if necessary. The brake fluid level must lie within the
-MAX-MIN marking- .
Subsequent work
Subsequent work
1. Fit wheel → 440519 Removing and installing wheels - chapter on "installing" .
Information
New brake pads require a bedding-in period of approx. 200 km! Only then do they achieve their best friction and
wear coefficient! During this period, the brakes should only be subjected to full stress at high speed in
emergencies!
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove wheel. → 440519 Removing and installing wheel
WARNING
Danger of accident if brake pads of the wrong quality are installed.
This can result in longer braking distances and more wear.
→ Use only the type-specific brake pads in the Porsche Spare Parts Catalogue.
The core of the warning contact line must not be left exposed! Worn insulation is not significant !
If necessary, remove a little brake fluid from the expansion tank by suction to prevent overflow when the disc
brake pad is pushed back!
1. Remove lock (securing clip) -arrow- at top from retaining pin and
remove retaining pin -direction arrow- inwards
WARNING
Danger of accident if old parts are fitted on brake caliper.
This can cause malfunctions.
→ Fit new expanding spring, new retaining pin and new retaining pin screw on the brake caliper.
Check disc brakes for wear. For wear limits see Technical Data → 46 TW Technical data/brake wear limits -
chapter on "Technical values"!
The core of the warning contact line must not be left exposed! Worn insulation is not significant!
If necessary, remove a little brake fluid from the expansion tank by suction to prevent overflow when the disc
brake pad is pushed back!
1. If necessary, push brake piston back into its original position using the piston resetting fixture (replaces
P83) NR.144, see Workshop Equipment Manual, Chapter 2.4.
6. Check brake fluid level and correct if necessary. The brake fluid level
must lie within the → see figure MAX - MIN marking.
New brake pads require a bedding-in period of approx. 200 km! Only then do they achieve their best friction and
wear coefficient! During this period, the brakes should only be subjected to full stress at high speed in
emergencies!
Subsequent work
Mount wheel. → 440519 Removing and installing wheel
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Information
Brake disc wear assessment - General
Normally, brake disc replacement is necessary after the thickness falls below the minimum. In rare, isolated cases
(of very high loads for long periods) replacement may be necessary due to crack formation. To a certain extent
these cracks may be rated as not important. A description is given in the following sections of when to replace
brake discs.
Cracks arise through material fatigue due to frequent and extreme thermal expansion fluctuations. Particularly in
cases of very high loads for long periods, these thermal expansion fluctuations produce internal stresses. The
result may be cracks in the friction surface. These cracks allow relaxation of the friction disc, so that the speed at
which the cracks develop is very slow.
The cracks run from the centre of the friction surface to the (inner and outer) edges of the brake disc. As different
vehicle types have different brake disc sizes, differences arise for the maximum crack length limits.
Larger cracks impair braking comfort and reduce brake disc strength,
therefore making brake disc replacement necessary as a precaution.
Irrespective of the crack length, the brake disc must be replaced if the
crack has extended as far as the outer and/or inner edge of the disc.
New brake pads require a bedding-in period of approx. 200 km! Not until then do they achieve their best friction
and wear coefficient. During this period, the brakes should be subjected to full stress when travelling at high
speed only in emergencies. The slightly reduced braking effect must be compensated for by increased pressure
on the brake pedal. The same also applies after replacing or machining brake discs.
Checking
Different vehicle types have different brake disc sizes. This produces differences for the maximum crack length
limits.
The length of a crack can be measured with a steel rule, for example. -steel rule-
Note
Irrespective of the crack length, the brake disc must be replaced if the crack has extended as far as the outer
and/or inner edge of the disc.
As a precaution, brake discs must
be replaced when:
the → Maximum crack
length: 0.5 x a mm (a =
friction surface width in mm) is
exceeded!
the → Maximum crack
width: 1 mm is exceeded!
the → Maximum crack
depth: 1.5 mm is exceeded!
Note
Normally, brake discs are used until the maximum wear dimension is reached. → 46 Technical data/brake wear
limits Only in a few exceptional cases is it advisable to skim the brake discs (if there is deep scoring or corrosion
of the friction surface). In this case only the disc brake dressing machines approved by Porsche AG are to be
used (see Workshop Equipment Manual, Chapter 3.4).
Only rework the brake discs symmetrically, evenly from both sides!
As the pressure force of a brake piston on the brake pad varies in magnitude, different areas of wear arise on the
friction surface. The brake disc can basically be divided into two areas of wear:
– Measure the brake discs with a suitable micrometer at a minimum of three different places ( -A, B, C- ),
offset by 120°.
Note
Fasten dial gauge set with ball joint arm to wheel bearing housing.
For checking lateral runout two
adapters are used. The brake disc
and wheel hub can be measured
with these.
Note
The front face of the wheel hub must not be corroded. If necessary, clean
with fine emery cloth.
– Measure the wheel hub lateral runout at the front face of the wheel Dial gauge on brake disc
hub. You should always measure the external and internal diameters
of the wheel bolt area.
1. Remove the brake disc. → 465019 Removing and installing the front brake disc
2. Fit the adapter dial gauge set with ball joint arm NR.147-1 at a suitable position on the wheel bearing
housing. Fit the dial gauge with some preload.
– Measure the thickness tolerance with a suitable micrometer screw within the braking surface at approx. eight
points.
Dial gauge on wheel hub
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove wheel. → 440519 Removing and installing wheel
Note
In order to gain better access for removal of the brake calliper, it is beneficial to turn the wheels fully either to
the right or the left.
1. Release retainer for plug of wear indicator on wheel carrier.
3. Push brake pad back slightly and evenly with piston resetting
fixture (replaces P83) NR.144, see Workshop Equipment Manual,
Chapter 2.4 -direction arrow- . Make sure that no brake fluid runs
out of the supply tank - if necessary, remove by suction.
4. Undo brake caliper on wheel carrier and hang it in a suitable place in
the wheel well (do not open the brake hydraulics!).
Distinguishing characteristic: Part No.! The flat surface of the brake discs is marked with R = right or L = left.
1. Check that all parts are in perfect condition and replace them if necessary.
2. Clean the levelling and centring surfaces on the brake disc and wheel hub. Then apply a very thin coat of
Optimoly TA to the centring surface on the wheel hub.
4. Fit the brake caliper. Replace the brake caliper fastening screws after each removal. Observe correct
tightening torque → 46 TW Tightening torques for brake mechanics - chapter on "Technical values".
8. Check brake fluid level and correct if necessary. The brake fluid level
must lie within the → see figure MAX - MIN marking.
Subsequent work
Mount wheel. → 440519 Removing and installing wheel
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Information
Brake disc wear assessment - General
Normally, brake disc replacement is necessary after the thickness falls below the minimum. In rare, isolated cases
(of very high loads for long periods) replacement may be necessary due to crack formation. To a certain extent
these cracks may be rated as not important. A description is given in the following sections of when to replace
brake discs.
Cracks arise through material fatigue due to frequent and extreme thermal expansion fluctuations. Particularly in
cases of very high loads for long periods, these thermal expansion fluctuations produce internal stresses. The
result may be cracks in the friction surface. These cracks allow relaxation of the friction disc, so that the speed at
which the cracks develop is very slow.
The cracks run from the centre of the friction surface to the (inner and outer) edges of the brake disc. As different
vehicle types have different brake disc sizes, differences arise for the maximum crack length limits.
Larger cracks impair braking comfort and reduce brake disc strength,
therefore making brake disc replacement necessary as a precaution.
Irrespective of the crack length, the brake disc must be replaced if the
crack has extended as far as the outer and/or inner edge of the disc.
New brake pads require a bedding-in period of approx. 200 km! Not until then do they achieve their best friction
and wear coefficient. During this period, the brakes should be subjected to full stress when travelling at high
speed only in emergencies. The slightly reduced braking effect must be compensated for by increased pressure
on the brake pedal. The same also applies after replacing or machining brake discs.
Checking
Different vehicle types have different brake disc sizes. This produces differences for the maximum crack length
limits.
The length of a crack can be measured with a steel rule, for example. -steel rule-
Note
Irrespective of the crack length, the brake disc must be replaced if the crack has extended as far as the outer
and/or inner edge of the disc.
As a precaution, brake discs must
be replaced when:
the → Maximum crack
length: 0.5 x a mm (a =
friction surface width in mm) is
exceeded!
the → Maximum crack
width: 1 mm is exceeded!
the → Maximum crack
depth: 1.5 mm is exceeded!
Note
Normally, brake discs are used until the maximum wear dimension is reached. → 46 Technical data/brake wear
limits Only in a few exceptional cases is it advisable to skim the brake discs (if there is deep scoring or corrosion
of the friction surface). In this case only the disc brake dressing machines approved by Porsche AG are to be
used (see Workshop Equipment Manual, Chapter 3.4).
Only rework the brake discs symmetrically, evenly from both sides!
As the pressure force of a brake piston on the brake pad varies in magnitude, different areas of wear arise on the
friction surface. The brake disc can basically be divided into two areas of wear:
– Measure the brake discs with a suitable micrometer at a minimum of three different places ( -A, B, C- ),
offset by 120°.
Note
Fasten dial gauge set with ball joint arm to wheel bearing housing.
For checking lateral runout two
adapters are used. The brake disc
and wheel hub can be measured
with these.
Note
The front face of the wheel hub must not be corroded. If necessary, clean
with fine emery cloth.
Dial gauge on brake disc
– Measure the wheel hub lateral runout at the front face of the wheel
hub. You should always measure the external and internal diameters
of the wheel bolt area.
1. Remove the brake disc. → 465319 Removing and installing rear brake disc
2. Fit the adapter dial gauge set with ball joint arm NR.147-1 at a suitable position on the wheel bearing
housing (schematic representation of front axle). Fit the dial gauge with some preload.
– Measure the thickness tolerance with a suitable micrometer screw within the braking surface at approx. 8
Dial gauge on wheel hub
points.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove wheel → 440519 Removing and installing wheel.
2. Remove brake caliper → 474119 Removing and installing rear brake caliper - chapter on "Installing".
3. Turn the brake disc in such a way that the adjustment device
becomes visible. With a → see figure screwdriver through the bore,
turn the adjustment device towards "release".
4. Push brake pad back slightly and evenly with piston resetting
fixture (replaces P83) NR.144, see Workshop Equipment Manual,
Chapter 2.4 -direction arrow- .
Distinguishing characteristic: Part No.! The flat surface of the brake discs is marked with R = right or L = left.
1. Check that all parts are in perfect condition and replace them if necessary.
2. Clean the levelling and centring surfaces on the brake disc and wheel hub. Then apply a very thin coat of
Optimoly TA to the centring surface on the wheel hub.
3. Fit the brake disc. Observe tightening torque. → 46 TW Tightening
torques for brake mechanics - chapter on "Technical values".
5. Fit the brake caliper. Replace the brake caliper fastening screws after
each removal. Observe tightening torque. → 46 TW Tightening
torques for brake mechanics - chapter on "Technical values".
6. Position disc brake pads by operating the brake several times.
7. Check brake fluid level and correct if necessary. The brake fluid level
must lie within the → see figure MAX - MIN marking.
Subsequent work
Mount wheel. → 440519 Removing and installing wheel
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Move control pedal to zero position (pull release). Parking brake is released.
2. Remove trim panel in the sill area → 680519 Removing and installing inner door sill trim - chapter on
"removing" .
3. Remove lower A-pillar trim panel panel → 705719 Removing and installing A-pillar trim panel panel - chapter
on "removing".
4. Remove centre console → 681719 Removing and installing centre console - chapter on "removing" .
5. Remove cover in the driver's footwell → 702219 Removing and installing cover under dashboard - chapter
on "removing".
Installation Location:
Front brake cable -C-
Note
Front brake cable means: From the release for the foot-operated parking brake to the deflector under the
centre console.
The actuating pedal for the foot-operated parking brake does not have to be removed to do this.
1. Fix the adjustment device using an → see figure auxiliary pin (max. 3.5 mm Ø) . In other words: press the
adjustment device together -arrow- until the assembly bores are covered and the auxiliary pin can be
inserted → 466019 Removing and installing actuator for foot-operated parking brake - chapter on
"removing". Only remove the ball head of the brake cable -1- when the brake cable has been removed from
the deflector (centre console) .
2. Lift the front carpet (do not bend) and push the rear carpet aside.
3. Remove securing clip on the deflector -arrow- .
4. Unclip securing clip using a → see figure screwdriver and remove it.
5. Remove the ball head from the latch on the deflector. To do this
→ see figure place an open-ended wrench (a/f 22) on the deflector
hexagon and turn it until the end of the cable can be removed
(arrow).
6. To remove the brake cable, press the retaining lugs on the securing clip -arrows- ) together and pull it out of
the bracket.
Note
The cable retainer on the actuating pedal for the front brake cable
cannot be removed and is not available as an individual part. During
removal, carefully press the → see figure cable retainer back using a
small screwdriver.
8. Remove the brake cable at the actuating pedal. To do this, press the
retaining lugs on the securing clip -arrows- together and pull the
brake cable out of the bracket. Push the ball head out of the latch.
Carefully press the securing lug back using a small screwdriver and
remove the brake cable .
9. Remove the brake cable under the wiring harness and under the air guide.
1. Lay the brake cable under the wiring harness -arrow- and under the air guide -arrow- .
2. Fit the ball head to the latch on the actuating pedal. Make sure that the securing lug is not damaged.
3. Push the ball head into the latch on the deflector. To do this → see figure use an open-ended wrench (a/f 22)
on the deflector hexagon and turn it until the end of the cable can be inserted.
4. Engage the → see figure securing clip into the bracket on the
deflector and make sure it is fitted correctly. Observe the following
note for this purpose:
Note
Damaged securing clips must be replaced. The brake cable can
become detached if the securing clip is defective.
5. Install cover of driver's footwell → 702219 Removing and installing cover under dashboard - chapter on
"Installing" and lay the carpet .
2. Install lower A-pillar trim panel panel → 705719 Removing and installing A-pillar trim panel panel - chapter
on "Installing" and fit the trim panel in the sill area → 680519 Removing and installing inner door sill trim -
chapter on "Installing".
3. Remove → see figure auxiliary pin from the actuator of the foot-
operated parking brake and install cover on actuating module.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove lower trim panel in footwell (with diagnostic socket and footwell lighting) and the trim panel support
on the bulkhead (only inserted) → 702219 Removing and installing cover under dashboard - chapter on
"removing" .
2. Remove lower dashboard trim panel → 701919 Removing and installing trim panel under dashboard -
chapter on "removing".
3. Remove side cover of dashboard (fuse box) and the lower A-pillar
trim panel → 702419 Removing and installing trim panel for front side
section - chapter on "removing". To remove the A-pillar trim panel,
only partial removal of the >> trim panel for front side section << is
required!
1. Loosen bowden cable for releasing the FPB at the dashboard (at the side). Pull the release lever slightly.
Then, slide the bowden cable in the direction of travel and take the bowden cable sleeve out of the bracket.
2. Remove protective cover (two screws) over the foot-operated parking brake pedal.
The → see figure cable retainer for the front brake cable cannot be
removed and is not available as an individual part. Push the cable
retainer back carefully during removal (Point 8).
5. Lay the carpet aside. Remove fastening screws of FPB pedal (two
M8 screws). Next remove the FPB pedal. The pedal must not be
actuated (removal aid).
Note
Replace micro-encapsulated screws.
If the bowden cable or front brake cable are damaged, replace them.
3. Tighten the fastening screws to 23 Nm (17 ftlb.). Take off the additional tie-wraps used during removal.
5. Engage the bowden cable for releasing the FPB in the lever.
7. Lay carpet. Fit cover (protective grille) of foot-operated parking brake pedal and protective cover (two
screws) over the pedal.
Subsequent work
1. Fit lower A-pillar trim panel and side cover of dashboard→ 702419 Removing and installing trim panel for
front side section - chapter on "installing".
Remove lower dashboard trim panel → 701919 Removing and installing trim panel under dashboard - chapter on
"installing".
2. Remove lower trim panel in footwell (with diagnostic socket and footwell lighting) and the trim panel support
on the bulkhead (only inserted) → 702219 Removing and installing cover under dashboard - chapter on
"installing" .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Move control pedal of the foot-operated parking brake to the zero position. To do this, pull the release lever on
the dashboard.
2. Remove cover in the footwell → 702219 Removing and installing cover under dashboard - chapter on
"removing".
Rear brake cable -E- means: From the deflector under the centre console -D- to the Quickfit lock in the brake drum
on the rear wheel.
Note
When performing various tasks on the rear axle, e.g. removing and installing the wheel bearing housing, the
brake cable only needs to be detached without removing the entire brake cable. The description at the end of
the installation chapter, → 467955 Replacing rear brake cable for foot-operated parking brake - chapter on
"detaching", can be used for this purpose.
1. Fix the adjustment device using an → see figure auxiliary pin (max. 3.5 mm Ø ) . In other words, press the
adjustment device together -arrow- until the assembly bores coincide and the auxiliary pin can be inserted
→ 466019 Removing and installing pedal for foot-operated parking brake - chapter on "Removing". The cover
of the pedal need not be removed. The auxiliary pin can be inserted through the cover .
2. Remove centre console → 681719 Removing and installing centre console - chapter on "Removing" .
5. Pull the balancing clip of the deflector completely back, against the
direction of travel, and loosen the → see figure small fastening screw.
6. To remove and disengage the ball head(s) of the cables, the nut on
the threaded rod -arrow- can be loosened by a few turns. (Note the
number of turns! Mark the nut, if necessary)
7. Push the ball head out of the balancing clip of the deflector in -direction of arrow- and remove it sideways.
Press the sleeve of the cable in the interior (two plastic lugs) gently together and push through to the rear,
against the direction of travel.
8. Remove the → see figure sheetmetal clips of the hand brake cables at the fuel tank (underbody) with a
screwdriver.
11. Remove the brake cable. Do not loosen the circlip! To do this, insert a
screwdriver between the sleeve of the brake cable and the wheel
bearing housing .
12. Pull the sleeve of the cable -arrow- as far as possible out of the wheel
bearing housing.
13. Push the cable gently into the brake drum. Use a small screwdriver inserted through the brake disc opening to
press the retaining spring and hexagon on the expander lever upwards and at the same time pull the brake
cable out of the brake drum.
In this case, loosen the → see figure circlip carefully (do not remove
from brake cable!) and move by one ring groove. The circlip and cable
are only available as an assembly. The settings should be the same
on both sides.
If the circlip has been damaged during removal/fitting (e.g. bent out of
shape, circlip bent up), the entire cable must be replaced.
1. Insert the end of the cable with the hexagon into the Quickfit on the
wheel bearing housing. Push the cable at the other end (ball head)
towards the wheel bearing housing until the hexagon engages audibly
in the Quickfit. Ensure a good seal.
2. Look through the brake disc opening with a small lamp to check that the end of the cable (hexagon) is seated
correctly in the Quickfit.
3. Make sure that the circlip is seated correctly -arrow- . (Shown here on
the removed cable.)
4. Push the end of the cable with the ball head through the underbody
and clip in the two plastic tabs. Mount the ball head in balancing clip in
the passenger compartment. Fit the nut on the threaded rod using the
number of turns noted previously. Ensure correct cable routing.
5. Remove the → see figure auxiliary pin from the FPB pedal.
6. Perform a function test. If necessary set the brake shoes to the basic setting → 468316 Adjusting foot-
operated parking brake - chapter on "adjusting".
Note
Tolerances in the cables (different length right to left) can cause the balancing clip to be out of line when the
foot-operated parking brake (FPB) is actuated. Press the FPB pedal gently until the cables are tensioned.
Only then should you tighten the small screw (Torx T15) on the balancing clip by hand .
7. Install centre console → 681719 Removing and installing centre console - chapter on "installing" .
8. Install cover in the footwell → 702219 Removing and installing cover under dashboard - chapter on
"installing".
Installation Location:
1. Fix the adjustment device using an → see figure auxiliary pin (max. 3.5 mm Ø ) . In other words: press the
adjustment device together -arrow- until the assembly bores are covered and the auxiliary pin can be inserted
→ 466019 Removing and installing pedal for foot-operated parking brake - chapter on "removing".
3. Remove the relevant rear wheel → 440519 Removing and installing wheel - chapter on "removing".
4. Remove the brake cable from the guide of the rear axle housing and loosen it by moving it to and fro.
Note
The screw plug -arrow- of the brake disc obscures the view of the Quickfit. The Quickfit is positioned at
approx. 3 o'clock to the right and approx. 9 o'clock to the left.
The brake discs do not have to
be removed to disengage the
brake cables.
6. Remove the brake cable. Do not loosen the circlip! To do this, insert a
screwdriver between the sleeve of the brake cable and the wheel
bearing housing .
7. Pull the sleeve of the cable as far as possible out of the wheel bearing
housing.
8. Push the cable gently into the brake drum. Use a small screwdriver
inserted through the brake disc opening to press the retaining spring
and hexagon on the expander lever upwards and at the same time
pull the brake cable out of the brake drum.
2. Look through the brake disc opening with a small lamp to check that
the end of the cable (hexagon) is seated correctly in the Quickfit.
4. To fit the brake cable correctly into the guides on the underbody and
on the rear axle carrier, the brake cable must be taut. To do this, tug
on the brake cable, against the direction of travel, in the cable sleeve
area (thickening) on the rear axle carrier. This gives clearance
between the brake cable and the cardan shaft.
Subsequent work
Mount the wheel → 440519 Removing and installing wheels - chapter on "installing" and tighten to the specified
tightening torque.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Checking
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.
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!
Adjustments must only be carried out at the two rear wheel adjustment devices. No adjustment may be made
on the pedal module or on the Z deflector on the centre console.
Ensure that the FPB cables are routed correctly.
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 rear wheels must be removed to gain access to the adjustment device → 440519 Removing and installing
wheel - chapter on "removing".
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- !
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!
3. Adjust 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).
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Raise vehicle → 40 V0 Lifting the vehicle - chapter on "preliminary work".
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!
Adjustments must only be carried out at the two rear wheel adjustment devices. No adjustment may be made
on the pedal module or on the Z deflector on the centre console.
To do this, measure from the left seat rail up to the lower edge of the pedal plate of the FPB!
1. Depress → Adjustment value: 40 mm +5 mm . If this dimension is reached, the wheels must be able to turn
without grinding the brake pads.
2. Depress → Adjustment value: 75 mm +5 mm . If this dimension is reached, the wheels must be fixed. If the
wheels can still turn, the FPB must be adjusted!
The rear wheels must be removed so that the adjustment device can be accessed! → 440519 Removing and
installing wheel
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
pressed back slightly and evenly with the piston resetting fixture
(replaces P83) NR.144, see Workshop Equipment Manual, Chapter 2.4
-direction arrow- !
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!
3. Adjust 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, modify the
adjustment device until the wheel can no longer be turned. Then
unscrew 6 teeth (wheels must be free to turn).
Subsequent work
Mount rear wheels. → 440519 Removing and installing wheel
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove wheel → 440519 Removing and installing wheel.
2. Remove brake calliper and brake disc → 465319 Removing and installing rear brake disc.
Replacing
Removing
Note
The cover (grille) on the actuating mechanism of the foot-operated parking brake (FPB) does not need to be
removed. The auxiliary pin can be inserted through the cover (grille).
Watch out for sharp edges in the area of the actuating mechanism for the foot-operated parking brake (FPB).
1. Remove cover over actuating mechanism for foot-operated parking brake (FPB).
2. Move pedal of foot-operated parking brake (FPB) into zero position. To do this, pull the release lever on the
dashboard.
3. Fix the adjustment device using an -auxiliary pin with diameter of max. 3.5 mm- . In other words: press
the adjustment device together -Arrow- until the assembly bores are covered and the auxiliary pin can be
inserted → 467955 Replacing rear brake cable for foot-operated parking brake.
Adjustment device for foot-operated
parking brake
4. Remove some of the brake cable. Do not loosen the circlip! To do this, insert a -screwdriver- between the
sleeve of the brake cable and the wheel bearing housing.
5. Pull the -sleeve of the cable- as far as possible out of the wheel
bearing housing.
6. Then push the cable gently into the expanding-lock. Use a small
screwdriver to press the retaining spring and hexagon down at the
expander lever and at the same time pull the brake cable out of the
expanding-lock.
ATTENTION
Risk of injury (e.g. crushing) when removing and installing springs.
Danger of injury and damage.
Springs can pop out.
The edges of springs may be sharp.
ATTENTION
Risk of injury (e.g. crushing) when removing and installing springs.
Danger of injury and damage.
Springs can pop out.
The edges of springs may be sharp.
1. Install brake disc and brake calliper → 465319 Removing and installing rear brake disc.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
46 Brake disc measurement sheet - as of MY 2003
- Information
Information
Note
Notes on checking and measurement points can be found in:
→ 46 Technical data/brake wear limits
→ 465002 Checking front brake discs (wear assessment)
→ 465302 Checking rear brake discs (wear assessment)
To document the measured result, a copy or print of the data card illustrated can be used. The data cards cannot
be ordered.
Note
Actual values that are identical in all versions are already entered!
In the course of further development these values may change. If necessary, carry out a check and insert the
new values accordingly. → 46 Technical data/brake wear limits
2. Before measurement (Test 1 through Test 3), enter the general data, vehicle type and the missing nominal
values (new brake disc thickness / brake disc wear limit) into the data card.
3. Carry out measurements (actual status) and enter the values in the alignment card.
4. If brake discs are to be replaced, carry out Test 2 with the new discs again and enter the latest values in a
new data card.
Measuring prerequisites
– Note the labour operation numbers.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1. Move the driver's seat back.
2. Remove the lower cover. → 702219 Removing and installing cover under dashboard - chapter on
"removing" . At the diagnostic socket just unclip the connector from the rear.
Note
For better accessibility, remove the lower cover under the steering column.
Installation Location:
3. Remove the holder for the stop light switch and unclip the connector
-arrow- → 943619 Removing and installing stop light switch - chapter
on "removing".
5. Remove relay carrier -arrows- → 979019 Removing and installing relay carrier, plenum panel E-box - chapter
on "removing".
6. Remove both control units -arrow- , on the right side under the dashboard → 966619 Removing and installing
Kessy/immobilizer control unit - chapter on "removing", → 971019 Removing and installing vehicle electrical
system control unit - chapter on "removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 971019
21 Removing and installing vehicle electrical system control unit - chapter on "removing" [9PAAJ1].
7. Release the support (relay carrier/Kessy control unit/immobilizer/vehicle electrical system control unit) (left
side and front engaged, right side screwed) and let them hang. In this way, the brake pedal shaft can be
pushed out toward the centre of the vehicle (cardan tunnel).
8. Disengage the brake pushrod from the brake pedal mounting using
the unlocking tool T10189 . Observe the following procedure for this
purpose:
-1- - unlocking tool T10189 for brake pedal.
– Position the unlocking tool T10189 -1- so that the fork sits in correct position in the brake pedal mounting (in
the inset, the fork in contact, view against the direction of travel).
– When pressing forward on the lever (unlocking tool) (in direction of travel!), the brake pedal mounting is
pressed apart and the ball of the pushrod is released. At the same time, pull the brake pedal to the rear
(against the direction of travel!) and release the brake pedal from the pushrod.
9. Counter the brake pedal shaft (pin) -arrows- on the right side and slightly loosen to the left -(arrows)- . The
nut remains on the brake pedal shaft to protect the thread.
10. Loosen the two upward running struts of the articulated strut and let them hang. To do this, remove the
retainer on each retaining pin, remove the retaining pins, and let the struts hang down.
11. Using a hammer, force out the brake pedal shaft a few millimetres with short, heavy blows from left to right.
Brake pedal released from the
pushrod
12. Place a screwdriver under the head of the brake pedal shaft (right side). Remove the nut, and lever out the
brake pedal shaft carefully toward the centre of the vehicle (cardan tunnel).
13. Carefully press out the brake pedal shaft so that the brake pedal can be removed.
Note
Do not grease or spray the brake pedal shaft (pin).
For vehicles with automatic transmission a spacer tube is used instead of the clutch pedal.
Use new lock nuts.
Subsequent work
Remove the lower cover → 702219 Removing and installing cover under dashboard - chapter on "installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Adjusting
Note
The brake pushrod play is strictly specified.
The brake pushrod can be removed from the brake pedal with the unlocking tool T10189 .
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
Removing
If necessary, remove a little brake fluid from the expansion tank by suction to prevent overflow when the disc
brake pad is pushed back!
Installing
WARNING
Danger of accident if old parts are fitted on brake caliper.
Fit new expanding spring, new retaining pin and new retaining pin screw on the brake caliper.
→
WARNING
Danger of accident if brake pads of the wrong quality are installed.
Use only the type-specific brake pads in the Porsche Spare
Parts Catalogue.
Check disc brakes for wear; for wear limits see → 46 Technical
data/brake wear limits!
The core of the warning contact line must not be left exposed! Worn insulation is not significant!
1. If necessary, push brake piston back into its original position using the piston resetting fixture (replaces
P83) NR.144, see Workshop Equipment Manual, Chapter 2.4.
Note
Make sure that the retaining pin is inserted in the correct position! The flat side surfaces prevent the retaining
pin from twisting in the brake caliper.
3. Install expanding spring. Centre the retaining pin in the bore with the
M8 auxiliary screw. To do so, press retaining pin back with auxiliary
screw and push retaining pin through. Remove auxiliary screw and fit
fastening screw at retaining pin with specified tightening torque → 46
Tightening torques for brake mechanics!
4. Install warning contact line at disc brake pads and expanding spring -arrows- . The cable guide in the
expanding spring must be at the bottom!
5. Position disc brake pads by operating the brake several times.
6. Check brake fluid level and correct if necessary. The brake fluid level
must lie within the -MAX-MIN marking- .
Subsequent work
Subsequent work
1. Fit wheel → 440519 Removing and installing wheel - chapter on "installing" .
Information
New brake pads require a bedding-in period of approx. 200 km! Only then do they achieve their best friction and
wear coefficient! During this period, the brakes should only be subjected to full stress at high speed in
emergencies!
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove wheel. → 440519 Removing and installing wheel
WARNING
Danger of accident if brake pads of the wrong quality are installed.
This can result in longer braking distances and more wear.
→ Use only the type-specific brake pads in the Porsche Spare Parts Catalogue.
The core of the warning contact line must not be left exposed! Worn insulation is not significant!
If necessary, remove a little brake fluid from the expansion tank by suction to prevent overflow when the disc
brake pad is pushed back!
WARNING
Danger of accident if old parts are fitted on brake caliper.
This can cause malfunctions.
→ Fit new expanding spring, new retaining pin and new retaining pin
screw on the brake caliper.
Check disc brakes for wear. For wear limits see Technical Data → 46
TW Technical data/brake wear limits - chapter on "Technical values"!
The core of the warning contact line must not be left exposed! Worn
insulation is not significant!
Note
Make sure that the retaining pin is inserted in the correct position.
The flat side surfaces prevent the retaining pin from twisting in the
brake caliper.
3. Install expanding spring. Centre the retaining pin in the bore with the
M8 auxiliary screw. To do so, push retaining pin back with auxiliary
screw and push retaining pin through. Remove auxiliary screw and fit
fastening screw at retaining pin with specified tightening torque → 46
TW Tightening torques for brake mechanics - chapter on "Technical
values"!
4. Install warning contact line at disc brake pads and expanding spring -arrows- . The cable guide in the
expanding spring must be at the bottom!
6. Check brake fluid level and correct if necessary. The brake fluid level must lie within the → see figure MAX -
MIN marking.
New brake pads require a bedding-in period of approx. 200 km! Only then do they achieve their best friction and
wear coefficient! During this period, the brakes should only be subjected to full stress at high speed in
emergencies!
Subsequent work
Mount wheel. → 440519 Removing and installing wheel
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
Removing
If necessary, remove a little brake fluid from the expansion tank by suction to prevent overflow when the disc
brake pad is pushed back!
1. Remove lock (securing clip) -top arrow- from retaining pin and
remove retaining pin -direction arrow- inwards.
Installing
WARNING
Danger of accident if old parts are fitted on brake caliper.
Fit new expanding spring, new retaining pin and new safety bracket on the brake calliper.
→
WARNING
Danger of accident if brake pads of the wrong quality are installed.
Use only the type-specific brake pads in the Porsche Spare Parts Catalogue.
Note
The back of the pad backing plates must not be greased.
Check disc brakes for wear; for wear limits see → 46 Technical data/brake wear limits.
The core of the warning contact wire must not be left exposed! Worn insulation is not significant.
If necessary, remove a little brake fluid from the expansion tank by suction to prevent spilling when the disc
brake pad is pushed back.
1. If necessary, push brake piston back into its original position using the piston resetting fixture (replaces
P83) NR.144, see Workshop Equipment Manual, Chapter 2.4.
3. Fit expanding spring, retaining pin -direction arrow- and lock (safety
bracket) -top arrow- at top of retaining pin.
6. Check brake fluid level and correct if necessary. The brake fluid level must lie within the
-MAX-MIN marking- .
Subsequent work
Subsequent work
1. Fit wheel → 440519 Removing and installing wheels - chapter on "installing" .
Information
New brake pads require a bedding-in period of approx. 200 km! Only then do they achieve their best friction and
wear coefficient! During this period, the brakes should only be subjected to full stress at high speed in
emergencies!
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove wheel. → 440519 Removing and installing wheel
WARNING
Danger of accident if brake pads of the wrong quality are installed.
This can result in longer braking distances and more wear.
→ Use only the type-specific brake pads in the Porsche Spare Parts Catalogue.
The core of the warning contact line must not be left exposed! Worn insulation is not significant !
If necessary, remove a little brake fluid from the expansion tank by suction to prevent overflow when the disc
brake pad is pushed back!
1. Remove lock (securing clip) -arrow- at top from retaining pin and
remove retaining pin -direction arrow- inwards
WARNING
Danger of accident if old parts are fitted on brake caliper.
This can cause malfunctions.
→ Fit new expanding spring, new retaining pin and new retaining pin screw on the brake caliper.
Check disc brakes for wear. For wear limits see Technical Data → 46 TW Technical data/brake wear limits -
chapter on "Technical values"!
The core of the warning contact line must not be left exposed! Worn insulation is not significant!
If necessary, remove a little brake fluid from the expansion tank by suction to prevent overflow when the disc
brake pad is pushed back!
1. If necessary, push brake piston back into its original position using the piston resetting fixture (replaces
P83) NR.144, see Workshop Equipment Manual, Chapter 2.4.
6. Check brake fluid level and correct if necessary. The brake fluid level
must lie within the → see figure MAX - MIN marking.
New brake pads require a bedding-in period of approx. 200 km! Only then do they achieve their best friction and
wear coefficient! During this period, the brakes should only be subjected to full stress at high speed in
emergencies!
Subsequent work
Mount wheel. → 440519 Removing and installing wheel
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Information
Brake disc wear assessment - General
Normally, brake disc replacement is necessary after the thickness falls below the minimum. In rare, isolated cases
(of very high loads for long periods) replacement may be necessary due to crack formation. To a certain extent
these cracks may be rated as not important. A description is given in the following sections of when to replace
brake discs.
Cracks arise through material fatigue due to frequent and extreme thermal expansion fluctuations. Particularly in
cases of very high loads for long periods, these thermal expansion fluctuations produce internal stresses. The
result may be cracks in the friction surface. These cracks allow relaxation of the friction disc, so that the speed at
which the cracks develop is very slow.
The cracks run from the centre of the friction surface to the (inner and outer) edges of the brake disc. As different
vehicle types have different brake disc sizes, differences arise for the maximum crack length limits.
Larger cracks impair braking comfort and reduce brake disc strength,
therefore making brake disc replacement necessary as a precaution.
Irrespective of the crack length, the brake disc must be replaced if the
crack has extended as far as the outer and/or inner edge of the disc.
New brake pads require a bedding-in period of approx. 200 km! Not until then do they achieve their best friction
and wear coefficient. During this period, the brakes should be subjected to full stress when travelling at high
speed only in emergencies. The slightly reduced braking effect must be compensated for by increased pressure
on the brake pedal. The same also applies after replacing or machining brake discs.
Checking
Different vehicle types have different brake disc sizes. This produces differences for the maximum crack length
limits.
The length of a crack can be measured with a steel rule, for example. -steel rule-
Note
Irrespective of the crack length, the brake disc must be replaced if the crack has extended as far as the outer
and/or inner edge of the disc.
As a precaution, brake discs must
be replaced when:
the → Maximum crack
length: 0.5 x a mm (a =
friction surface width in mm) is
exceeded!
the → Maximum crack
width: 1 mm is exceeded!
the → Maximum crack
depth: 1.5 mm is exceeded!
Note
Normally, brake discs are used until the maximum wear dimension is reached. → 46 Technical data/brake wear
limits Only in a few exceptional cases is it advisable to skim the brake discs (if there is deep scoring or corrosion
of the friction surface). In this case only the disc brake dressing machines approved by Porsche AG are to be
used (see Workshop Equipment Manual, Chapter 3.4).
Only rework the brake discs symmetrically, evenly from both sides!
As the pressure force of a brake piston on the brake pad varies in magnitude, different areas of wear arise on the
friction surface. The brake disc can basically be divided into two areas of wear:
– Measure the brake discs with a suitable micrometer at a minimum of three different places ( -A, B, C- ),
offset by 120°.
Note
Fasten dial gauge set with ball joint arm to wheel bearing housing.
For checking lateral runout two
adapters are used. The brake disc
and wheel hub can be measured
with these.
Note
The front face of the wheel hub must not be corroded. If necessary, clean
with fine emery cloth.
– Measure the wheel hub lateral runout at the front face of the wheel Dial gauge on brake disc
hub. You should always measure the external and internal diameters
of the wheel bolt area.
1. Remove the brake disc. → 465019 Removing and installing the front brake disc
2. Fit the adapter dial gauge set with ball joint arm NR.147-1 at a suitable position on the wheel bearing
housing. Fit the dial gauge with some preload.
– Measure the thickness tolerance with a suitable micrometer screw within the braking surface at approx. eight
points.
Dial gauge on wheel hub
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove wheel. → 440519 Removing and installing wheel
Note
In order to gain better access for removal of the brake calliper, it is beneficial to turn the wheels fully either to
the right or the left.
1. Release retainer for plug of wear indicator on wheel carrier.
3. Push brake pad back slightly and evenly with piston resetting
fixture (replaces P83) NR.144, see Workshop Equipment Manual,
Chapter 2.4 -direction arrow- . Make sure that no brake fluid runs
out of the supply tank - if necessary, remove by suction.
4. Undo brake caliper on wheel carrier and hang it in a suitable place in
the wheel well (do not open the brake hydraulics!).
Distinguishing characteristic: Part No.! The flat surface of the brake discs is marked with R = right or L = left.
1. Check that all parts are in perfect condition and replace them if necessary.
2. Clean the levelling and centring surfaces on the brake disc and wheel hub. Then apply a very thin coat of
Optimoly TA to the centring surface on the wheel hub.
4. Fit the brake caliper. Replace the brake caliper fastening screws after each removal. Observe correct
tightening torque → 46 TW Tightening torques for brake mechanics - chapter on "Technical values".
8. Check brake fluid level and correct if necessary. The brake fluid level
must lie within the → see figure MAX - MIN marking.
Subsequent work
Mount wheel. → 440519 Removing and installing wheel
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tightening torques
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
DANGER
Porsche Stability Management does not work without values for the current brake pressure.
Danger of personal injury and material damage when the hydraulic unit is not calibrated.
→ After assembling the hydraulic unit, a static test and a swap test must be carried out with the Porsche System
Tester.
→ After assembly of the brake master cylinder or the hydraulic unit, the pressure sensor must be calibrated with
the Porsche System Tester.
Note
Observe brake fluid quality. Use only new DOT 4 brake fluid.
The brake fluid change interval is two years, using Super DOT 4 brake fluid.
This brake fluid is available under the following part numbers: Container quantity: 1 litre = 000.043.203.66. 30
litres = 000.043.203.67.
1. Open reservoir.
2. Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure is
approx. 2.0 bar.
Note
Always bleed both bleeder valves on the brake caliper.
4. Use a transparent hose and a collecting bottle to check the escaping brake fluid is clean and free of air
bubbles and to determine the amount of brake fluid used.
5. Open each bleeder valve until clear, bubble-free brake fluid emerges.
6. Tighten the bleeder valves to the specified tightening torque and remove the bleeder hoses.
7. Remove bleeding device from brake fluid reservoir and screw cap on.
The brake fluid level in the brake fluid reservoir must be between the
MIN and MAX markings once the vehicle has been filled and bled.
Adjust the brake fluid level if necessary.
Note
If the pedal travel is too long or the pedal feels too soft when applied, carry out the following procedure.
Also carry out this procedure if the brake hydraulic system was largely empty.
Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure is approx.
2.0 bar.
1. Open bleeder valve at rear on right-hand side, then push the brake pedal all the way down about 5 times and
tap the brake caliper gently several times with a rubber hammer during the bleeding process.
2. Hold for 2 - 3 seconds after each depression, then release pedal slowly. After applying pedal for the fifth time,
hold pedal down and close bleeder valve.
5. Remove bleeding device from brake fluid reservoir; correct brake fluid level is necessary.
6. Generate vacuum in brake booster by starting engine. Check brake-pedal travel and pedal feel.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
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- .
Note
The brake fluid level must not exceed the MAX mark.
Observe brake fluid quality. Use only new DOT 4 brake fluid.
Note
Observe brake fluid quality. Use only new DOT 4 brake fluid.
The brake fluid change interval is two years using Super DOT 4 brake
fluid.
Drain brake fluid from every brake caliper at both bleeder valves.
4. Continue changing the brake fluid at the brake calipers. Do so in the following sequence: rear right/rear
left/front right/front left.
5. Open every bleeder valve until clear, bubble-free brake fluid emerges and until the corresponding change
quantity per brake caliper is reached (approx. 250 cm3).
6. Use a transparent hose and a collecting bottle to check the escaping brake fluid accurately for cleanliness,
freedom from air bubbles and to determine the brake fluid used.
8. Switch off bleeding device and remove the adapter on the brake fluid
reservoir. The brake fluid level in the brake fluid reservoir must be
between the MIN and MAX markings once the vehicle has been filled
and bled. Adjust the brake fluid level if necessary.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove both wiper arms → 922519 Removing and installing wiper arm - chapter on "removing".
2. Remove cover in engine compartment → 700219 Removing and installing front cover (engine compartment)
- chapter on "removing".
Installation Location:
Note
Before disconnecting the connector from the brake master cylinder
(pressure sensor) first wipe off any moisture with a lint-free cloth.
In order to catch escaping brake fluid, place a cloth under the brake
booster.
Note
In the case of assembly work on the hydraulic connections, the electrical plug connections on the brake
master cylinder must always be connected. This prevents the plug connections on the brake master cylinder
and the inside of the plugs being splashed with brake fluid or water.
Clean any plug connections that have become dirty or damp during removal or fitting with a lint-free cloth.
Brake fluid on electrical contacts (even thinned brake fluid) leads to corrosion and may cause faults in the
system.
Remove any escaping brake fluid immediately; if necessary, rinse with water and dry.
The brake master cylinder is located on the left in the engine compartment, under the cowl panel cover -arrow- on
the brake booster .
1. Push both connectors -arrows- on the plenum panel (oxygen sensor cable) from the bracket.
2. Open the cable clip on the plenum panel and loosen the cable.
3. Remove left plenum panel partition.
4. Disconnect the connector on the cover of the brake fluid reservoir and remove the cover -arrow- .
5. Remove the brake fluid from the brake fluid reservoir by suction. To do this, use a double-acting hand pump.
6. Bend both → see figure lugs on the brake fluid reservoir carefully
outward and pull off the container upwards.
7. Loosen the brake lines from the brake master cylinder.
8. Unclip the brake line on the brake master cylinder to the left front
wheel and remove the fastening clip -arrow- .
10. Remove the connector of the pressure sensor at the underside of the
brake master cylinder.
DANGER
Porsche Stability Management does not work without values for the current brake pressure.
Danger of personal injury and material damage when the hydraulic unit is not calibrated.
→ After assembly of the brake master cylinder or hydraulic unit, the pressure sensor must be calibrated with
the Porsche System Tester.
→ To do this, calibrate the pressure sensor in the menu >> PSM >> Calibration >> Pressure sensor <<.
→ The security code is stored under menu >> PSM >> Actual values >> Security code <<. The code is entered
in the last four positions.
Note
Cleanliness is essential when installing the brake master cylinder so that dirt does not enter the system. This
can cause faults in the system.
1. Connect the connector of the pressure sensor to the underside of the brake master cylinder.
2. Fit the brake master cylinder loosely on the brake booster. Ensure sealing ring is seated properly between
the brake master cylinder and the brake booster. Insert pushrod in the correct position in the brake master
cylinder.
4. Fit the brake master cylinder on the brake booster and fit the brake lines. Fit the brake line of the left front
wheel with the clip to the brake master cylinder.
5. Attach the brake fluid reservoir (observe sealing rings) and check for
correct seating of the lugs.
6. First insert the seal of the plenum panel and then slide the plenum
panel in from above. Fit the fastening screws.
8. Push the two large connectors into the bracket on the plenum panel.
9. Connect the connector to the cover of the brake fluid reservoir.
Subsequent work
1. Fit the right and the rear covers → 700219 Removing and installing front cover (engine compartment) -
chapter on "installing" and the cowl panel → 664419 Removing and installing cowl panel - chapter on
"installing".
2. Install both wiper arms → 922519 Removing and installing wiper arm - chapter on "installing".
3. Bleed the vehicle → 470107 Bleeding the brake system - chapter on "bleeding". After the bleeding operation,
do not top up the brake fluid level above -MAX- .
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1. Raise vehicle → 40 V0 Lifting the vehicle - chapter on "preliminary work".
Installation Location:
Note
To gain better access for removal of the brake caliper, it helps to turn
the steering fully either to the right or the left.
1. Push brake pad back slightly and evenly with piston resetting
fixture (replaces P83) NR.144, see Workshop Equipment Manual,
Chapter 2.4 -direction arrow- .
2. Release and unclip the plug from the wear indicator -arrow- . Loosen
the brake line on the brake caliper -arrow- and collect brake fluid in a
suitable container. Close off the line with suitable plugs.
Note
Never use an impact bolter to loosen and tighten the brake calliper on
the wheel carrier.
Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier.
Subsequent work
1. Bleed the brake system → 470107 Bleeding the brake system - chapter on "bleeding".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
Brake caliper
1. Push brake pad back slightly and evenly with piston resetting
fixture (replaces P83) NR.144, see Workshop Equipment Manual,
Chapter 2.4 -direction arrow- .
2. Release and unclip the connector from the wear indicator -arrow- .
3. Remove cable holder for the brake line and wear indicator -arrow- .
Note
Never use an impact bolter to
loosen and tighten the brake
calliper on the wheel carrier.
Note
Replace screws and lock nuts.
Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier.
Subsequent work
1. Bleed the brake system → 470107 Bleeding the brake system - chapter on "bleeding".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1. Switch off the ignition.
2. Remove both wiper arms → 922519 Removing and installing wiper arm - chapter on "removing".
3. Remove cover in engine compartment → 700219 Removing and installing front cover (engine compartment)
- chapter on "removing".
4. Remove cowl panel → 664419 Removing and installing cowl panel - chapter on "removing".
Note
During assembly work on hydraulic connections, the electrical plug
connections on the hydraulic unit must always be connected. This
prevents the plug connections on the hydraulic unit and the inside of
the connectors being splashed with brake fluid or water.
The brake master cylinder is located on the left in the engine compartment, under the cowl panel cover -arrow- ,
together with the brake booster.
Note
Brake lines are to be sealed with suitable plugs.
To catch escaping brake fluid, place a cloth under the brake booster.
2. Open the cable clip on the plenum panel and loosen the cable.
4. Partly remove the brake master cylinder (brake fluid reservoir) → 471519 Removing and installing brake
master cylinder - chapter on "removing".
5. Disconnect the vacuum line on the brake booster.
7. Unclip the cable over the brake booster from the holders -arrows-
and pull upwards.
8. Unclip the brake line to left front wheel out of the bracket underneath
the relay carrier.
10. Loosen two M6 screws on the lower closing panel -arrows- (upper
screw head covered) (shown here when fitting the brake booster,
relay carrier removed).
Note
If the rubber bushes stick to the holders in the plenum panel when
removing the relay carrier, these must be fitted in the openings
provided before being inserted again.
11. Release the relay carrier in the plenum panel and hinge it to one
side. To do this, unclip the six plugs in the rear section of the relay
carrier ( -arrow- and right marking).
12. Remove the cover under the dashboard on the driver's side in the
passenger compartment → 700219 Removing and installing front
cover (engine compartment) - chapter on "removing".
13. Pull off connector of stop light switch -arrow- and remove the complete holder → 943619 Removing and
installing stop light switch - chapter on "removing".
Note
When loosening the pushrod of the brake booster with the unlocking
tool T10189 from the pushrod of the pedal, the tool must first be
inserted and then the brake pedal pulled out into the passenger
compartment.
14. Release brake pedal from pushrod -arrow- of brake booster with
unlocking tool → 460519 Removing and installing brake pedal -
chapter on "removing".
15. To do this, insert the unlocking tool T10189 from below into the
bush on the brake pedal -arrow- .
16. Remove the four M8 lock nuts on the brake booster in the passenger
compartment.
17. Remove front left wheel housing liner.
18. Disconnect the brake line in the wheel housing on the intermediate
piece -arrow- and seal with suitable plugs.
19. Remove both clips for the air-conditioning lines in the plenum panel.
20. Pull the brake lines to the brake master cylinder and left front wheel carefully forward and press the air-
conditioning lines down. Make sure that the boot on the brake booster -arrow- does not get stuck in the duct
to the passenger compartment.
21. Carefully pull out the brake booster -direction arrow- to the front.
DANGER
Porsche Stability Management does not work without values for the current brake pressure.
Danger of personal injury and material damage when the hydraulic unit is not calibrated.
→ After assembly of the brake master cylinder or hydraulic unit, the pressure sensor must be calibrated with
the Porsche System Tester.
→ To do this, calibrate the pressure sensor in the menu >> PSM >> Calibration >> Pressure sensor <<.
→ The security code is stored under menu >> PSM >> Actual values >> Security code <<. The code is entered
in the last four positions.
Note
Absolute cleanliness is necessary when installing the brake booster as well as the adjacent brake master
cylinder. Dirt can cause faults in the system.
Bleed the vehicle according to the plan to ensure full operation of the brake system.
When inserting the brake booster, make sure the brake pushrod and boot are guided correctly.
1. Carefully pull the brake lines of the brake master cylinder and left front wheel forward and press the air-
conditioning lines downward.
3. Guide the → see figure pushrod of the brake booster through the opening in the passenger compartment.
Ensure the boot is seated correctly.
4. Fit the brake booster with four M8 fastening nuts.
5. Press the brake pedal forward until the ball socket engages in the mounting point.
6. Fit the holder for the stop light switch and connect the connector
-arrow- → 943619 Removing and installing stop light switch -
chapter on "installing".
7. Fit the cover on the driver's side → 700219 Removing and installing
front cover (engine compartment) - chapter on "installing".
8. Fit the clamps of the air-conditioning lines.
Note
If the rubber bushes stick to the holders in the plenum panel when
removing the relay carrier, these must be fitted in the openings
provided before being inserted again.
9. Install relay carrier in the plenum panel. To do this, fit the six
connectors in the rear section of the relay carrier ( -arrow- and right
marking).
10. Join the closing panel using the two M6 screws -arrows- (shown
here when fitting the brake booster - relay carrier removed).
11. Join the brake line in the front left wheel housing (remove sealing plugs).
12. Install front left wheel housing liner.
13. Clip the brake line to left front wheel in the bracket underneath the
relay carrier in the plenum panel.
14. Connect the plug on the distance sensor of the brake booster.
16. Fit brake master cylinder → 471519 Removing and installing brake
master cylinder - chapter on "installing" .
17. Fit left plenum panel partition.
Subsequent work
1. Fit the right and the rear covers → 700219 Removing and installing front cover (engine compartment) -
chapter on "installing" and the cowl panel → 664419 Removing and installing cowl panel - chapter on
"installing".
2. Install both wiper arms → 922519 Removing and installing wiper arm - chapter on "installing".
3. Bleed the vehicle → 470107 Bleeding the brake system - chapter on "bleeding".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tightening torques
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Fundamentals
Various kinds of damage can be caused to steering columns in the event of accidents or driving conditions similar
to accidents. In cases where the steering column shows no external damage it can be difficult to detect damage.
This damage represents an unacceptable risk for the vehicle, since it could lead to failure of the steering system.
To decide whether the steering column of a vehicle involved in an accident must be replaced or may continue to
be used, the following guidelines are helpful.
Assessment of the steering column of a vehicle involved in an accident
The steering column may remain in the vehicle if all the following conditions are met:
No visible damage (breakage, cracks, deformation) to such front-axle parts as steering arms, steering gear,
steering column mountings, steering wheel and airbag unit, wheel rims, wheel bearing housing (wheel carriers),
tie rods, steering shaft or to the points on the body where wheel suspension parts are bolted on.
No impermissible rise in torque and no jamming or catching when the steering gear is turned from stop to stop.
When the steering is turned, the front wheels must be free (front axle raised) and, in addition, the engine must be
switched off (pump of power steering undriven).
The steering column does not catch/jam when turned separately without steering gear.
The steering column must be replaced by a new or exchange unit if one of the following points applies:
Fire damage.
Additionally, for vehicles with electrically adjustable steering columns, if the adjustment does not function perfectly
(the axial and/or vertical adjustment time from stop to stop is too long, unusual noises are heard in this area).
The steering intermediate shaft and/or a universal joint is touching another component or has clearance of less
than 5 mm with it.
The steering wheel is more than 10° out of line when the marking for steering centre position overlaps → 44
Suspension alignment, complete section on "Adjust toe".
steering gear,
tie rods,
steering arms,
spring struts,
wheel carriers,
control arms,
then the steering column must be checked according to the criteria listed above.
Checking the steering column of a vehicle involved in an accident
The gap dimension on the steering column can still be used. The → Gap
dimension: 0.5 mm -X- . If the gap is larger, the steering column must be
replaced. In this case, the driver has been forced against the steering
wheel in an accident and has pushed the carriage in the steering module
in the direction of travel. The gap dimension X can be checked using a
feeler gauge.
If the listed criteria are insufficient for a decision, we recommend that the
steering column be replaced by a new or exchange unit.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
Fundamentals
Various kinds of damage can occur to the steering gear in the event of accidents or driving conditions similar to
accidents. In cases where the steering gear shows no external damage it can sometimes be difficult and costly to
detect damage. Nevertheless, this damage represents an unacceptable risk for the vehicle, since it could lead to
failure of the steering system.
A comprehensive check on all individual parts of the steering gear is not usually feasible due to the relatively high
cost and is not possible using ordinary workshop resources. Instead, consideration must be given to the condition
of other components that are easier to check.
To decide whether the steering gear of a vehicle involved in an accident must be replaced or may continue to be
used, the following guidelines are helpful.
The steering gear may remain in the vehicle if all the following conditions are met:
No visible damage to such front-axle parts as wheel rims, spring struts, wheel carriers, control arms, steering
arms, tie rods, suspension subframe, the steering shaft or to the points on the body where wheel suspension
parts are bolted on.
No impermissible rise in torque and no jamming or catching when the steering gear is turned from stop to stop.
When the steering is turned, the front wheels must be free (front axle raised) and, in addition, the engine must be
switched off (pump of power steering undriven).
The steering gear must be replaced by a new or exchange unit if one of the following points applies:
Steering-gear mountings
Tie rods
Steering arms
Spring struts
Wheel carriers
Control arms
Suspension subframe
If the listed criteria are insufficient for a decision, we recommend that the steering gear be replaced with a new or
exchange unit.
If a workshop's intended exchange of steering gear is refused by a customer or insurer for reasons of costs, an
expert or - if this is impossible abroad, the importer - should be called in at the cost of the refusing party. If the
decision contradicts the guideline, we recommend that a memorandum be drawn up on the point and that it be
countersigned by the expert.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
General
Note
Rack-and-pinion steering gear and servo pump must not be repaired or dismantled!
Damage to the power steering is caused by a shortage of oil in the hydraulic system. Even small leaks can cause
the fluid to escape and damage the servo pump as a result of the high oil pressure in the hydraulic circuit.
Grunt-like noises on turning the steering to full lock or foam formation in the reservoir indicate a shortage of oil
and/or the absorption of air. Before filling the reservoir, any existing leaks must be eliminated . In this case the oil
level in the reservoir must be checked with the engine running as well as stopped! If the oil level drops to the
bottom of the reservoir or bubbles rise up, then there is air in the hydraulic system.
Use only Pentosin CHF 11 S in the reservoir. Pentosin CHF 11 S can be ordered under the following part number:
Quantity supplied 1 litre = 000.043.203.33.
ATTENTION
Increased risk of accident and material damage if too much Pentosin CHF 11 S is filled in or if Pentosin
CHF 11 S comes into contact with the coolant hoses when filling or topping up.
Overfilling of the system with consequent overflow of Pentosin CHF 11 S onto coolant hoses and
other components may occur.
→ Before inspecting the fluid level, run the engine for approx. 20 seconds. Multiple steering operations
(manoeuvring) will alter the fluid level in the reservoir! Check the fluid level.
→ If coolant hoses come into contact with Pentosin, thoroughly clean them with water IMMEDIATELY.
→ Replace visibly swollen coolant hoses.
Note
The reservoir is located at the front left of the engine compartment.
Check the fluid level (Pentosin CHF 11 S) when the engine is stopped and
cold (approx. 20°C).
Pentosin tank in the engine
compartment
The fluid level must be between the MAX and MIN marks → see figure .
1. Start engine and run it at idle speed for approx. 20 seconds. Switch
off engine.
2. Open engine cover and the lid of the engine compartment cover.
4. Wipe dipstick. Close and then reopen cap. The fluid level must be in
the indicated range (MAX/MIN level at approx. 20 °C). Top up with
Pentosin if necessary.
Bleeding
4. Then turn the steering to the left and to the right. Hold the steering on
full lock for approx. 30 seconds on each side until the level no longer
drops. Continually check the fluid level and fill to the MAX mark again
if necessary.
5. Lower vehicle onto the wheels. Briefly start the engine, let it run for
approx. 1 second and add Pentosin again. This procedure causes
the fluid level in the reservoir to fall rapidly, so constantly add
Pentosin CHF 11 S. The reservoir must not be sucked dry.
6. If the fluid level in the reservoir does not fall any further when the
engine is briefly turned over, start the engine and let it run at idling
speed.
7. Turn steering on full lock several times to left and right at idling speed and observe the fluid level during this
procedure (second worker required). If it continues to fall, add fluid until the level in the reservoir remains
constant and no more air bubbles circulate in the reservoir when the steering wheel is turned.
8. Switch engine off and set the correct fluid level. This must be between the MAX and MIN markings.
When the correct level has been reached, no air bubbles must be circulating in the reservoir and the fluid level
must no longer drop.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Disconnect battery. → 90 Work instructions after disconnecting the battery
2. Remove steering wheel airbag unit. → 695819 Removing and installing driver's airbag unit - chapter on
"removing"
ATTENTION
Increased risk when handling airbag modules.
Injury and material damage may occur if airbag units are not
handled correctly → 69 AW Safety regulations for vehicles with
airbag and belt tensioner - chapter on "General warning notes".
Note
Disconnect steering wheel heating if fitted on vehicle.
Note
The steering wheel is made of magnesium alloy! The tightening torques must be strictly observed!
Airbag unit must lock with an audible click! Check by pulling at airbag unit!
Subsequent work
1. Install steering wheel airbag unit. → 695819 Removing and installing driver's airbag unit - chapter on
"installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
2. Angle the steering wheel 90° to the left, press the left → see figure
locking lug forward with a screwdriver and unclip it.
3. Angle the steering wheel 90° to the right, press the right locking lug
forward with a screwdriver and unclip it.
4. Pull the top steering column trim back -arrow- and tip it up slightly so
that the steering column trim can be removed from the front guide.
5. Use a small screwdriver to unclip the retaining strip for the gap cover (leather) -arrows- . Remove the top
steering column trim.
6. Remove the steering column adjusting lever.
7. Remove the two fastening
screws -arrow- from the lower
steering column trim at the left
and right next to the steering
column.
Note
On vehicles with an electrically adjustable steering column, unlock
and pull off the connector of the steering column actuator -arrow- .
Note
Install in reverse order.
After installation, check the gap and seating of the steering column
trim and adjust as required.
1. Fit lower trim panel. If necessary, clip in the connector for the electric
steering column actuator. Fit the lower trim in the correct position
using the fastening screws.
2. Clip in the retaining strip for the gap cover, starting from one side.
3. Fit the upper cover at the instrument cluster and make sure that the locking lugs clip in correctly on the
steering wheel side.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Note
The fore-and-aft adjustment must be brought to the fully extended position for the electrically adjustable
steering column. The vertical adjustment must be moved to the centre position. This will improve access to
the fastening screws on the mounting bracket.
1. Disconnect the battery. → 9000IN Work instructions after disconnecting the battery - section on
"Disconnecting"
Installation Location:
Steering column detached
ATTENTION
Increase risk when handling airbag modules.
Injury and material damage may occur if airbag units are not
handled correctly → 6900AW Safety regulations for handling
airbag and belt tensioner units - section on "General warning
notes".
1. Remove driver's airbag unit. To do this, turn the steering wheel 90° from the centre position. Press on
retaining clips with a screwdriver. Turn the steering wheel another 180° and repeat the procedure. Unclip
airbag unit → 695819 Removing and installing driver's airbag unit - chapter on "removing".
2. Turn the steering wheel to the straight-ahead position and remove → 481019 Removing and installing
steering wheel - chapter on "removing".
3. Remove cover from steering column switch and remove steering column switch → 945019 Removing and
installing steering column switch - chapter on "removing".
5. Remove lock nuts for mounting sealing bellows on bulkhead -arrows- (one lock nut hidden).
Mounting sealing bellows
6. Remove the two fastening screws of the holder for the stop light switch -arrows- .
7. Disconnect electric plug connections.
9. Remove fastening screws -1-4- on the mounting bracket and pull out complete steering column.
Note
Observe the tightening sequence of steering column at mounting bracket.
Once the battery is disconnected, perform the work required for full restoration of normal driving → 90 Work
instructions after disconnecting the battery.
Calibrate steering-angle sensor → 456015 Initialising and calibrating
steering-angle sensor.
The electronic steering column lock (ELV) must be taught using the
Porsche System Tester by selecting the menu items >> Kessy >>
Learning functions >> Teach ELV <<. You can get the necessary
immobiliser code from IPAS or from your importer by specifying the
vehicle identification number.
Always replace the fastening screw for the universal joint of the
steering column.
1. Insert the steering column and the fastening screws in the order
indicated -1, 2, 3, 4- on the assembly cross member.
2. Fit fastening screw to mounting bracket -arrow- (mount of upper universal joint), cardanic, free of warping
(movable in every direction).
3. Slide the steering shaft (universal joint) to correct position, steering gear in centre position, as far as it will go.
When fitted correctly and tension-free, the universal joint must be at a maximum distance -arrows- of 4 mm
from the outermost edge of steering gear dust boot.
Max.distance of universal joint from Mount of upper universal joint
steering
4. Fit steering-column switch → 945019 Removing and installing steering-column switch - chapter on
"installing".
5. Fit steering wheel → 481019 Removing and installing steering wheel - chapter on "installing".
6. Install airbag unit → 695819 Removing and installing driver's airbag unit - chapter on "installing".
Subsequent work
1. Fit the stop light switch support and the linings → 701919 Removing and installing lower dashboard cover -
chapter on "installing".
9PAAD1, 9PAAD7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Remove trim panel for steering column → 481319 Removing and installing trim panel for steering column -
chapter on "Removing"
1. Insert switch into the holder -Arrow A- and turn to the fastening
position -Arrow B- .
Install trim panel for steering column → 481319 Removing and installing
trim panel for steering column - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
To remove and install the sealing bellows, the steering column must be removed.
To do this, the catalytic converter on the side of the steering column must be removed. → 267319 Removing
and installing (main) catalytic converter - section on "Removing" [9PAAD1 9PAAD7]→ 267319 Removing
and installing (main) catalytic converter - section on "Removing" [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
When the intermediate steering shaft has been separated, make sure that everything remains extremely
clean. The grease on the individual parts must not be wiped off. If these individual parts are stored for a long
period of time, they must be protected from dust and dirt.
1. Remove steering column. → 481519 Removing and installing steering column - section on
"Removing" [9PAAJ1]→ 481519 Removing and installing steering column - section on "Removing" [9PAAD1
9PAAD7]→ 481519 Removing and installing steering column - section on "Removing" [9PAAE1 9PAAE7
9PAAF1]
Note
The steering columns must only be replaced as a complete unit. Individual components cannot be
disassembled and replaced.
Use the prescribed lubricant on the sliding part (see Parts Catalogue in Main Group 40305). This lubricant is
available under the following part numbers: Container quantity: one 10-gram tube = 000.043.205.44!
Use the prescribed lubricant at the sleeve contact point with the friction ring of the sealing sleeve (see Parts
Catalogue in Main Group 40305). This lubricant is available under the following part number: Container
quantity: one 30-gram tin = 999.917.557.00!
Fit together both parts of the steering column that were previously marked with -colour markings- .
The lower steering shaft must slide on the upper steering shaft
smoothly and without catching.
1. Fit the sealing bellows of the steering column in the correct position.
2. Slide the lower steering shaft onto the upper steering shaft → see
figure . Overcome the pressure point with a strong jerk.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Remove holder for stop light switch → 481519 Removing and installing steering column - chapter on
"Removing" [9PAAJ1]→ 481519 Removing and installing steering column - chapter on "Removing" [9PAAD1
9PAAD7]→ 481519 Removing and installing steering column - chapter on "Removing" [9PAAE1 9PAAE7
9PAAF1].
1. Release the left relay carrier -Arrows A- and pull it down and out -Arrow B- .
2. Press the relay carrier into the holder -Arrow A- until the locking tabs
engage audibly.
Install holder for stop light switch → 481519 Removing and installing
steering column - chapter on "Installing" [9PAAJ1]→ 481519 Removing
and installing steering column - chapter on "Installing" [9PAAD1 9PAAD7]
→ 481519 Removing and installing steering column - chapter on
"Installing" [9PAAE1 9PAAE7 9PAAF1].
Install trim panel under dashboard → 701919 Removing and installing trim
panel under dashboard - chapter on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Tools
2. For easier removal of the outer tie rod end, swivel the relevant wheel
carrier so that the tie rod extends fully. Remove the outer tie rod
joints with the press-out tool T10187. When pressing off, screw lock
nut on flush (protects the ball joint thread).
3. Right tie rod: Remove heat shield near joint boot of right tie rod.
4. Remove small clamp -arrow- of joint boot using assembly tool for
spring-band clamps NR.72.
5. Cut open and remove large clamp -arrow- of joint boot using a pair of side cutters.
6. Carefully pull the joint boot -see figure- outwards until the axial joint is accessible.
7. Disassemble axial joint -arrow- from the steering rack using open-jawed wrench insert a/f 38 NR.95-2 for
torque wrench and remove the complete tie rod.
Installing tie rod
Note
Install in reverse order.
The tie rods are delivered preset as an assembly (tie rod/tie rod joint).
If the joint boot is to be used again, before installing inspect for wear (cracks, slits) and check that sealing
surfaces are clean.
Identify position of tie rod joint on the (pre-) set tie rod and, in order to fit the joint boots and the small clamp,
remove/fit lock nut and tie rod joint.
During installation, insert new sealing rings -arrow- on the steering gear. Take care not to damage the
sealing ring when fitting the joint boot.
When fitting the ball joints, ensure that the bevel pinions are clean!
Remove dirt or grease on bevel pinions, e.g. with a lint-free cloth. Do
not use cleaning agent/solvent.
Fit joint boot (not twisted) and secure with new clamps -see figure- .
The clamp of the left joint boot must be clamped on the steering gear so
that the clamp lug -arrow- is in line with the steering shaft! Failure to
observe this can lead to constrictions in the area of the supply and return
lines.
The clamp of the right joint boot must be clamped on the steering gear so
that the clamp lug -arrow- points horizontally with the front axle carrier
(suspension subframe) in the direction of travel. Failure to observe this
can lead to constrictions in the area of the heat shield.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
Note
Fix steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering
wheel in centre position with steering wheel holder). If this is not done, the airbag contact unit will have to be
put in the centre position after installation of the steering gear → 945019 Removing and installing steering
column switch.
Before the feed and return lines are loosened, place a suitable container underneath to collect steering fluid.
2. Remove engine guard → 108019 Removing and installing engine guard - section on "Removing"
3. Remove wheel-housing liner → 505619 Removing and installing front wheel-housing liner - section on
"Removing" .
1. Remove the outer tie rod joints with the press-out tool T10187. When pressing off, screw lock nut on flush
(protects the ball joint thread).
4. Release rear mount of front-axle drive (right-hand side of vehicle). Lift front axle drive with a suitable jack
-see figure- (use wooden block or rubber base to prevent slipping. Remove fastening screw and lift front-
axle final drive just enough to access the bearing eye above the bolting point of the front axle carrier (do not
press the cardan shaft into the stop).
5. Re-insert fastening screw -arrow- (better access). The drive remains
in the raised position and the jack can be removed.
8. For easier removal of the steering gear, loosen the fastening nut on the coolant hoses. Then unclip coolant
hoses from brackets and lay them upwards -see figure- (cut-away view of steering gear shown here).
9. Remove heat shield and push steering gear -see figure- to the right, out of the subframe mounting points,
and turn to the rear.
10. Turn steering gear -arrow- to the rear by approx. 90-100 degrees.
11. Unclip the coolant hoses in the wheel housing from the retaining clip. Then carefully guide out steering gear
-see figure- through the left wheel housing.
WARNING
Risk of accident due to malfunction in PSM control range if steering-angle sensor is not calibrated or is
incorrectly calibrated.
Possibility of serious injury or material damage.
→ Calibrate steering-angle sensor with wheels in straight-ahead position using the Porsche System Tester
→ 456005 Initialising and calibrating steering-angle sensor.
→ If steering wheel has been removed, ensure that airbag spiral spring is in centre position → 945019
Removing and installing steering-column switch.
Note
When topping up or filling in Pentosin, make sure that it does not come into contact with the coolant hoses.
To avoid overflow caused by overfilling, observe the instructions → 48 Test and assembly work on power
steering.
If coolant hoses come into contact with Pentosin, clean them thoroughly with water IMMEDIATELY!
Tighten all threaded connections with the specified tightening torque values → 48 Tightening torques for steering.
Information
Installation instructions
Installation is in reverse order.
Replace fastening screw of steering shaft whenever it has been removed. Ensure it is fitted correctly. Insert
fastening screw (in correct position, not from the threaded side).
If the tie rods are to be reused, detach them from removed steering gear
and fit them on new steering gear. Insert new sealing rings -arrow- on
steering gear.
Note
The left clamp of the joint boot must be clamped so that the clamp lug
-arrow- is in line with the steering pinion.
The right clamp of the joint boot must be clamped so that the clamp
lug -arrow- points horizontally with the front axle carrier (suspension
subframe) in the direction of travel.
Fit joint boot (not twisted) and secure with new clamps -arrow- (use pliers for hose clamp NR.74, Workshop
Equipment Manual, commercially available tools).
Check the joint boot is not worn (cracks, slots) and that sealing surfaces are clean.
When fitting the ball joints, ensure that the conical seats are clean. Remove dirt or grease on conical seats, e.g.
with a lint-free cloth. Do not use cleaning agent/solvent.
Observe notes on steering-gear centre position in the section on front track adjustment in Repair Group 44 → 44
Suspension alignment, complete.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Raise the vehicle → Lifting the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the
vehicle [9PAAJ1].
2. Remove engine guard → 108019 Removing and installing engine guard - section on "Removing"
3. Remove front apron → 631519 Removing and installing front apron - section on "Removing"
1. Remove lateral air guides and the air guide at the top -arrows- .
Note
For the Cayenne Turbo, the centre piece of the air guide is a single-
part.
3.
5. Unclip the radiator for power steering from the mount -arrow- .
6. Bracket
7. Pull the
-retaining frame for radiator-
carefully to the front.
2. Retract the radiator for power steering into the mount -arrow- .
3. Clip the radiator for power steering into the bracket -arrow- . Ensure correct seating.
4.
5. Fit fastening screw -arrow- , connect hoses for power steering radiator and fit securing clamps. The hoses
must not be twisted in the process.
6. Together with bottom air guide, move bumper out of service position and into normal position → 503819
Removing and installing lock carrier and fit retaining bracket (front apron engine guard).
7. Install top air guide -arrows- and lateral air guides.
Subsequent work
Subsequent work
1. Fit front apron → 631519 Removing and installing front apron - section on "Installing" .
2. Mount engine guard → 108019 Removing and installing engine guard - section on "Installing"
3. Fill Pentosin and bleed steering → Test and assembly work on power steering.
4. Lower the vehicle → Lifting the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the
vehicle [9PAAJ1].
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
General
Position of hydraulic pump on engine
Damage to the power steering will occur if there is a shortage of oil in the hydraulic system. Even small leaks can
cause the hydraulic fluid to escape and damage the servo pump as a result of high oil pressure occurring in the
hydraulic circuit.
Grunt-like noises that can be heard when the steering is locked, or foam formation in the reservoir indicate a
shortage of oil and/or that air has also been sucked in. Before filling the reservoir, any existing leaks must be
eliminated on the suction side. Alternatively, the defective part on the pressure side should be replaced.
ATTENTION
Increased risk of accident and material damage if too much Pentosin CHF 11 S is filled in or if Pentosin
CHF 11 S comes into contact with the coolant hoses when filling or topping up.
Overfilling of the system with consequent overflow of Pentosin CHF 11 S onto coolant hoses and
other components may occur.
→ Before inspecting the fluid level, run the engine for approx. 20 seconds. Multiple steering operations
(manoeuvring) will alter the fluid level in the reservoir! Check the fluid level.
→ If coolant hoses come into contact with Pentosin, thoroughly clean them with water IMMEDIATELY.
→ Replace visibly swollen coolant hoses.
Preliminary work
Preliminary work
Note
The engine does not have to be removed in order to remove and install the hydraulic pump.
Loosen the pulley of the hydraulic pump before removing the drive belt.
1. Remove the left engine compartment cover. → 700219 Removing and installing front cover (engine
compartment) - chapter on "Removing"
Note
Before removing the cover of the air cleaner box , the intake manifold
must be disengaged from the air cleaner housing.
Loosen the pulley of the hydraulic pump before removing the drive
belt.
2. Slacken drive belt and remove from the pulley. → 137819 Removing and installing drive belt - chapter on
"Removing"
6. Clamp both lines to the hydraulic pump (suction line, pressure pipe)
with a hose clamp 3094 as close as possible to the hydraulic pump
as possible.
Note
In vehicles without Servotronic, the hydraulic system must be flushd with approx. two litres of Pentosin CHF
11 S .
When replacing the hydraulic pump observe the instructions in the Technical Information, Replacing servo
pump: Group 4, No. 5/03.
3. Fit drive belt in correct position and tension → 137801 Check drive belt - chapter on "Checking".
Subsequent work
Subsequent work
1. Fit air cleaner. → 242455 Replacing air-cleaner element - chapter on "Replacing"
3. Disconnect pressure pipe on the servo oil cooler (line leading to the hydraulic fluid tank). Have a suitable
plug ready and close the line (emerging hydraulic fluid!). Collect emerging hydraulic fluid in a suitable
container.
4. Fill the hydraulic fluid tank. Use a suitable auxiliary hose (approx. 10 - 15 cm, shop-made) to carry hydraulic
fluid that emerges during flushing into a suitable container (approx. 1.5 litres).
5. Flush the hydraulic system with the engine running by turning the steering several times to the right or left
stop, and adjust the hydraulic fluid level several times as required. The vehicle must be lowered onto the
wheels for this. The tank must not run empty while the engine is running (two workers required).
7. Bleed the hydraulic system with the engine running by turning the steering several times to the right or left
stop and adjust the hydraulic fluid level several times as required → 48 Testing and assembly work on
power steering.
8. Fit engine guard → 108019 Removing and installing engine guard - chapter on "installing".
9PAAD1, 9PAAD7
as of MY 2004
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Replacing
The hydraulic pump that was installed in vehicles up to model year 2005 will no longer be available as a spare
part. Only the new hydraulic pump will be offered as of model year 2006.
With the introduction of the new hydraulic pump from model year 2006, a modified suction connection will be used
for the suction pipe to the hydraulic reservoir, together with modified hose routing.
New hydraulic pump, including the new suction connection for the suction pipe to the hydraulic reservoir.
Vehicles up to model year 2005 must have the new hydraulic pump installed. To do this, the suction connection
on the hydraulic pump for the suction pipe to the hydraulic reservoir must be refitted.
Reason for the modified suction pipe to the hydraulic reservoir is the introduction of a new alternator as of model
year 2006. Should this require a conversion, you can find further information in the repair instructions → 272255
Replacing generator.
1. Refit hydraulic pump suction connection (if necessary up to model year 2005). Use new O-ring and hexagon-
headed bolt.
9PAAD1, 9PAAD7
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Notes
Note
A body is constructed so that it has deformable zones in the front and rear areas. These deformable zones
enable absorption of impact energy through their special design. The bearing structure in these areas is
adapted by a specific cross section reduction to provide optimum energy reduction in the event of an impact.
Due to the vehicle dimensions in the side area of the body, deformable zones cannot be provided for
absorbing energy. The impact energy can only be absorbed to a lesser extent here through the deformation
of doors and pillars. This is also the case for the roof area where only the roof skin can absorb impact energy
to a very small extent. In these areas, passenger protection is guaranteed by a rigid design of the passenger
cell.
The aim of this design is to absorb the impact energy in defined areas to keep the passenger cell as free of
damage as possible in the event of an accident. If the passenger cell has been deformed in the event of an
accident, extremely large reshaping forces can be expected. Repair work is often only possible in this case
by replacing body parts.
In general, an impact occurs diagonally or offset to the vehicle axle so that mixed forms are usually the result
of a front and side impact or a rear and side impact. The deformation is not always restricted to the impact
area. Due to inertia forces of masses, such as running gear, drive line, occupants of the vehicle and load or
the body itself, deformation can also occur in the opposite areas.
The following work sequence should provide assistance to correctly determine the scope of damage of
vehicles damaged in an accident.
3. Check unit mounts, running gear parts and steering parts for deformation and cracks
2. Visual inspection of the structural parts at the joints for gaping panel connections (e.g. entry area at the side
member under the rubber seal of the door)
3. Drive vehicle onto a lifting platform and raise. Measure the measuring points or reference points specified in
the repair check dimensions table diagonally, horizontally and vertically using a beam compass or an
electronic measuring system and compare with the specified values
→ Check dimensions for body repair
2. Check accessories for paint abrasion (accessories which have been in contact during the impact)
3. Drive vehicle onto a lifting platform and raise. Measure the measuring points or reference points specified in
the repair check dimensions table diagonally, horizontally and vertically using a beam compass or an
electronic measuring system and compare with the specified values
→ Check dimensions for body repair
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
9. Seal cavities
Repair
1. Cover undamaged areas of the vehicle
2. Disconnect battery
4. Reshape damaged area by straightening so that adjacent contours or gap dimensions correspond to the
standard condition
7. Fit new parts in, then check the gap dimensions with the accessories fitted
11. Grind visible weld seams flat; if necessary apply body solder or filler
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
DANGER
Risk of fatal injury! Vehicle can slip or topple off the lifting platform!
Risk of (fatal) injury due to vehicles slipping or tilting off lifting platforms may be caused by improper
alignment of the lifting platform arms or support plates, and by raising, supporting or removing units
on raised vehicles!
ATTENTION
Danger of material damage if the vehicle is raised incorrectly.
Lifting or supporting the vehicle at unsuitable take-up points can lead to material damage on the
vehicle.
Raising the vehicle in the sill area will lead to the deformation of body parts and to leakage in the
underbody area.
DANGER
Risk of fatal injury from high voltage during electric welding!
Danger of explosion and fire when welding in the area of highly inflammable materials.
Irritation to respiratory tracts from toxic zinc oxide emitted when welding galvanised steel!
Danger of injury from unintentional triggering of pyrotechnical safety components!
Danger of injury from weld spatters and UV light when welding!
→ Do not perform welding work in a damp environment or on wet ground; there is a risk of fatal injury from the
voltage being conducted through the human body. Persons with heart pacemakers should not perform
welding work. Use insulating underlays.
→ Remove highly flammable materials from the work area; if necessary, remove units with fuel-carrying parts
and protect work areas in the vehicle that are at risk of catching fire using fire-proof covers.
→ Ventilate the work area well.
→ Remove smoke gases with a suitable extraction system (refer to Workshop Equipment Manual).
→ Wear suitable protective equipment, such as protective clothing, gloves, a welding shield and, if necessary,
a protective mask.
→ For welding work, always disconnect both terminals on the battery. In the case of welding work in the
immediate vicinity of the control modules for pyrotechnical safety systems, remove the control modules
before beginning work.
→ In addition, the guidelines of the welding equipment manufacturer and the legal accident prevention
regulations and those of the mutual indemnity association (BGV D1) must be observed.
Safety instructions for flying sparks during grinding and welding work
ATTENTION
Danger of explosion and fire from flying sparks during grinding and welding work!
Danger of injury and danger of damage to vehicle parts and other vehicles due to flying sparks
→ Cover vehicle parts such as battery, fuel system, paintwork, glass and passenger compartment parts with
fire-proof covers and, if necessary, remove batteries and fuel-carrying components.
→ No other vehicles may be left unprotected in areas used for body repair!
→ When carrying out grinding and welding work near the fuel tank or fuel-carrying parts, make sure that these
parts do not heat up!
→ It is recommended to remove endangered parts!
→ Cover the welding area generously with fire-proof covers!
ATTENTION
Danger of injury! Bursting of the filled air-conditioning system during welding and brazing work!
Danger of injury due to the filled air-conditioning system bursting during welding and brazing work.
→ No welding, brazing or hot-air heating may be performed on parts of the filled air-conditioning system!
→ While drying after painting work, the temperature burden on the vehicle must not exceed two hours at a
maximum temperature of 80 °C!
→ Make sure that parts of the air-conditioning system do not heat up during welding or brazing work on the
vehicle!
→ In the case of extreme heating of filled air-conditioning systems, a very strong overpressure may be caused
in the system which may lead to an explosion.
ATTENTION
Danger of poisoning and injury when handling adhesive!
Danger of poisoning from breathing in vapours or from swallowing adhesive.
Risk of injury due to contact with skin or eyes.
ATTENTION
Material damage! Setting time of adhesive is not observed!!
Danger of damage to side section if setting time of adhesive is not observed.
ATTENTION
Danger of injury! Sharp-edge burrs on body and unit parts!
Injuries from sharp edges on body and unit parts.
→ Wear protective gloves when working in the area of sharp-edged body and unit parts!
DANGER
Danger of injury! Unintentional activation of airbag units!
Serious injury due to unintentional activation of airbag units!
→ The ground strap of the battery must be disconnected during work on the airbag system and alignment
bench jobs when the body is being repaired!
→ After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar tools must
not be started until after a waiting period of 1 minute!
ATTENTION
Material damage when removing plugs!
Danger of corrosion and of uncontrolled water penetration!
→ The body apertures are sealed with plugs at the factory, and must be sealed with the plugs provided once
more following disassembly or repair work!
ATTENTION
Danger of material damage when cleaning the water drainage hoses!
Water drainage hoses can be pushed out or deformed by blowing them out of the body during
cleaning!
→ When cleaning, only blow the water drainage hoses out with light compressed-air pressure!
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
In order to prevent the vehicle battery from discharging when visiting the workshop, a battery charging unit
with a rated current of at least 40 A must be connected as soon as the vehicle is unlocked.
Note
If electronic components, e.g. ABS control module, have been removed for repair work and are then reused,
they must undergo a functional check after fitting in accordance with existing specifications.
To protect electronic control units from overvoltage during electric arc welding, the following work regulations must
be observed:
When performing welding work: Remove plug connections on the engine, transmission, and airbag control
unit.
Remove clamp from negative terminal of battery and cover battery.
When welding work is extensive, electronic control units in the immediate vicinity of the welding point must be
removed.
Connect the ground connection of the electric arc welding equipment as near as possible to the welding point
on the part to be welded. Ensure that there are no electrically insulated parts between the ground connection
and the welding point.
Do not touch electronic control units or electric cables with the ground connection or the welding electrode.
Replacing control modules
The replacement of electronic control modules after an accident is necessary if at least one of the following
conditions is met:
The supporting surface or bracket is deformed (the unit shows no external damage).
Functional checks or self-diagnosis of the unit reveals the fault "Control module faulty".
Note
After repair work, the standard corrosion-inhibiting coating should only be restored with the corrosion-
inhibiting agents approved by the manufacturer. The following points must be observed for body repairs.
Always apply welding primer to both sides of the welding flange when resistance spot welding.
Prime repair areas from outside. Prime on both sides in the accessible areas.
Seal all sheetmetal overlaps, sheetmetal edges, butt joints, weld seams etc. with body sealant.
When replacing structurally bonded body parts, proceed according to the information in the respective repair
instructions.
Only apply body sealant to primed sheetmetal parts.
Apply top coat paint to the inside of the outer sheetmetal shell before welding. See "Paint build-up": → "Paint
Manual "
Build up paint on bright sheetmetal panels according to the painting methods described in the → "Paint
manual".
Repair or create standard undersealing by applying long-life undersealing material.
Preserve cavities in the repair area with cavity preservative after applying a top coat paint.
Check that the standard water drains (plugs) function correctly or clean them after the cavity preservation
material has dried.
All body repairs must be performed properly and according to the specific instructions defined by Porsche for
sheetmetal, painting and corrosion inhibition/preservation work. In order not to put the long-life guarantee at risk, a
paint condition report will be drawn up 2 years after delivering the vehicle. This condition report must be updated
every two years by every Official Porsche Centre.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Metalworking tools
Electrical equipment
-1- - Drill
-2- - Angle grinder, large
-3- - Angle grinder, small
-4- - Sander
-5- - Hot-air gun
Mechanical equipment
Compressed-air equipment
Welding equipment
-11- - Spotweld device and Multispot metalworking tool
-12- - MIG welder
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Resistance spot-welding
A - Plug weld
B - Stitch weld
C - Full weld
C - Intermittent full weld
Gas welding
A - Brazing
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Note
All dimensions are measured on the body shell (with units removed) middle hole or middle screw connection
point. The dimensions are measured directly and, therefore, are oblique dimensions. Refer to the relevant
vehicle views for the positions of the measuring points. The measuring points are identified for the right or left
side in relation to the direction of travel (viewed from above). Dimensions which are only specified for the left
side of the vehicle also apply to the mirror image on the right side of the vehicle.
Note
The specified dimensions are used only for an approximate estimation of possible structural damage. Repairs
to the vehicle must be done using an alignment system.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Note
Set gap dimensions on the lids, doors and covers, or accessories in accordance with the gap specifications.
Given a clearance in the openings that is too great or too small, the movable body parts or the accessories
must be centred accordingly.
Ensure that the gaps do not run in a wedge-shaped fashion or do not narrow at local points.
The given values are guidelines which should be observed as far as possible.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
ATTENTION
Corrosion due to entry of water though leaking or missing plugs!
Danger of material damage (corrosion) due to entry of water though leaking or missing plugs!
→ The body apertures are sealed with plugs in the factory, and must be sealed with the plugs provided once
more following disassembly or repair work!
Accessories
Rear lid
A - Rubber grommet hole Ø 20 mm
Unpainted bodyshell
A - Plug hole Ø 20 mm
B - Plug hole Ø 15 mm
C - Plug hole Ø 10 mm
D - Plug hole 15 x 20 mm
E - Plug hole Ø 30 mm
F - Plug hole 20 x 25 mm
Bottom of front of vehicle
A - Plug hole Ø 20 mm
B - Plug hole Ø 15 mm
E - Plug hole Ø 30 mm
A - Plug hole Ø 20 mm
E - Plug hole Ø 30 mm
Lower side member
A - Plug hole Ø 20 mm
E - Plug hole Ø 30 mm
G - Plug hole Ø 40 mm
Underside of floor
A - Plug hole Ø 20 mm
D - Plug hole 15 x 20 mm
E - Plug hole Ø 30 mm
F - Plug hole 20 x 25 mm
A - Plug hole Ø 20 mm
D - Plug hole 15 x 20 mm
E - Plug hole Ø 30 mm
Top of rear end
A - Plug hole Ø 20 mm
D - Plug hole 15 x 20 mm
A - Plug hole Ø 20 mm
B - Plug hole Ø 15 mm
D - Plug hole 15 x 20 mm
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Accessories
Note
In the case of repair work, accessories must be sealed before assembly (painting) according to the following
illustrations.
The sealing material, Würth's "Klebt und Dichtet" body sealant (see Parts Catalogue, Main Group 8), can be
applied directly to the components that are coated with KTL paint.
The seam seal can be painted over when it has reached approx. 70 % hardness (approx. 4 - 5 h at 20 °C, 50
% relative air humidity. Higher air humidity or dampening with water accelerates the hardening process).
The hardening can be checked with a nail test. Press a finger nail gently into the hardened sealing mass; if
this causes no damage to the sealing mass surface, the seam seal can be painted.
Front lid
Front door
In the areas marked -A- , smoothen the seam sealing compound following application using a spatula.
Rear door
In the areas marked -A- , smoothen the seam sealing compound following application using a spatula.
Rear lid
Unpainted bodyshell
Note
In the case of repair work, the unpainted body shell must be sealed before assembly (painting) according to
the following illustrations.
The sealing material, Würth's Klebt und Dichtet body sealant (see Parts Catalogue, Main Group 8), may only
be applied to primed sheetmetal.
Note
The seam sealing compound may only be applied thinly in the marked areas.
Note
The seam sealing compound may only be applied thinly in the marked areas.
Bottom of rear end
Top of rear end
Side of rear end
Tank tray
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
50 IN Undersealing - as of MY 2003
- Unpainted bodyshell
Unpainted bodyshell
A - 0.3 mm
B - 0.6 mm
C - 1.0 mm
D - 2.0 mm
Note
In the case of repair work, the standard chipping protection / undersealing of the body structure must be
restored according to the following illustrations after painting and prior to unit assembly.
Note
Apply the chipping protection / undersealing to the lower side member up to the top edge.
A - 0.3 mm
C - 1.0 mm
D - 2.0 mm
Underside of floor
A - 0.3 mm
B - 0.6 mm
C - 1.0 mm
A - 0.3 mm
B - 0.6 mm
C - 1.0 mm
A - 0.3 mm
B - 0.6 mm
C - 1.0 mm
A - 0.3 mm
B - 0.6 mm
C - 1.0 mm
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Accessories
Note
In the case of repair, the standard cavity preservation material must be applied to body accessories
according to the following illustrations.
The cavity preservation must be applied after completion of the assembly work.
Front door
Rear door
Unpainted bodyshell
Note
In the case of repair, the standard cavity preservation material must be applied to body accessories
according to the following illustrations.
In the case of repair work, cavity preservation must also be applied to the areas of the corresponding repair
points.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Note
After replacing the body or the sheetmetal parts in the area of the vehicle identification number (firewall), the
original vehicle identification number must be reimprinted onto the new body or the new sheet metal part.
An incorrectly imprinted vehicle identification number should be permanently crossed through with an X so
that it remains legible. In such cases, the applicable vehicle identification number must be imprinted above
the crossed out number in the replacement field.
For information on procedures for documenting a newly imprinted vehicle identification number in the vehicle
documents or in the case of questions concerning homologation, contact the importer of the respective
country involved.
In Germany, the newly imprinted vehicle identification number must be reported in writing to the vehicle
registration office immediately. We recommend cutting out the area containing the original vehicle
identification number and submitting it to the registration office as proof.
1. Location of the vehicle identification number
1.1. The vehicle identification number must be applied at the rear right
of the floorpan.
1.3. Field -A- is the standard location to apply the vehicle identification
number.
1.4. Field -B- is the spare space for a corrected vehicle identification
number.
2. Re-imprinting new vehicle identification number
Note
When imprinting the vehicle identification number, the floorpan must be supported by a suitable tool.
2.1.
2.2. Stamp the vehicle identification number with 8-mm letter/digit embossing tool with DIN 1451 close
spaced lettering NR.128-1 and delimiter marking punch 9693 in field -A- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
General
Structural bonding in the body shell means that the adhesive assumes functions of stiffness, crash strength and
endurance strength, whereby the characteristics of the body shell are positively influenced in a significant way. In a
conventional steel body shell, use is made of a high-strength, heat-hardening single-component epoxy resin
adhesive that fully hardens in the cathodic immersion paint drying oven. In the case of a repair, this adhesive is
replaced by a cold-hardening two-component epoxy resin adhesive, since the hardening temperatures necessary
for the single-component epoxy resin adhesive are not conceivable on an assembled vehicle. For both series
production of bodies-in-white and repair, structural bonded joints are regularly used in combined jointing
processes.
Resistance spot-welding combined with adhesive bonding and mechanical jointing processes
In the case of spot weld bonding for repair and series production, the entire extent of adhesive surfaces and spot
welds is replaced. In this case, before actually spot weld bonding, the unhardened adhesive must be displaced
from the joint area by an appropriate squeeze time. In the case of two-component adhesives, the hardening
reaction starts immediately after mixing and application; this increases the viscosity and so there is only a certain
time window in which spot weld bonding can be performed if the process is to be reliable. For this reason, all time-
intensive preliminary work (drilling, cutting to size, fixing etc.) on the parts to be joined must be performed before
application of adhesive and jointing. This also applies to mechanical jointing processes where the adhesive has to
be displaced from the joint area.
Note
In areas in which bonded flanges are spot-welded in an unhardened state, suction devices must be used due
to combustion products.
Areas that can only be accessed from one side must be joined with MAG plug-welds or MAG welded seams.
In these cases, no adhesive can be used in the vicinity of the welded
seam because this would burn and would have a negative effect on
the joint.
Once the spare parts have been attached, repair spotwelds must be placed
on the old spotwelds because there is no current flow possible in areas with
a hardened bonded layer. Welding procedures other than resistance spot-
welding are not permitted since the thermal effect would destroy the
bonded joint over a wide area.
Spot-welding body components
Processing adhesives
ATTENTION
Danger of poisoning and injury when handling adhesive!
Danger of poisoning from breathing in vapours or from swallowing adhesive.
Risk of injury due to contact with skin or eyes.
Note
In addition to this manual, observe the relevant job descriptions for body repairs!
Note
Bonding surfaces must be free from oil, old adhesive, dirt, moisture, and layers of paint and oxide.
To improve adhesion, the bonding surface must be roughened with sandpaper. Remove paint layers (cathodic
immersion painting) using dry sandpaper or fibre discs with a grain of 100 to 150.
The bare bonding surface must then be cleaned with a lint-free cloth soaked in acetone.
Leave cleaned areas to dry for approx. 1 -2 minutes. Bonding areas must be completely dry. Dispose of the
used, acetone-soaked cleaning cloth as special-category waste.
Ensure that clean gloves are worn when touching cleaned surfaces to avoid transferring sweat from the hands
and dirt onto the bonding area.
The jointing operation must take place directly after application of the adhesive in order to guarantee a high
quality and reliable bond. Otherwise the adhesive bead must be removed, with pre-treatment of the surface
and application of the adhesive being repeated.
Bonding operation
Minimum ambient and material temperature during working and hardening is 18° C. The coating thickness of
approx. 3 mm should not be exceeded; if necessary, spread the mixed adhesive on the bonding surface with a
spatula. Areas not coverd by cathodic immersion painting and exposed body panels must be brushed or filled with
structural adhesive.
Jointing operation
Join, fix and resistance spot-weld parts within the working time. The jointing operation must take place directly after
application of the adhesive in order to guarantee a high quality and reliable bond. Otherwise the adhesive bead
must be removed, with pre-treatment of the surface and application of the adhesive being repeated.
Hardening
The body structural adhesive used hardens at room temperature. Hardening can be accelerated by heat (e.g. with
an infra-red radiator in a painting booth). Do not load bonded parts until hardening is complete.
Disposal
Small amounts remaining after mixing and complete hardening may be disposed of as domestic waste.
Teromix gun
ATTENTION
Note
In addition to this manual, observe the relevant job descriptions for body repairs!
Releasing holder
2. Press sliding lock upwards
4.1. Insert double cartridge -C1- into the holder from above.
Engaging holder
6.
Removing lid
7. Fit processing nozzle.
7.1. Position processing nozzle -C2- and turn clockwise 90°.
8.1. By activating the valve of the gun grip, allow the piston rod to move
out slowly until the adhesive is visible in the processing pipe.
Note
In order to ensure that the substance is completely mixed, apply a 30
mm long adhesive bead of fresh adhesive to a piece of cardboard
before processing.
If the contents of the cartridge are not completely used up, the processing nozzle should be removed and the
cartridge sealed with the closure cap. In the event of later processing, a new processing nozzle must be used.
9.1.
ATTENTION
Note
In addition to this manual, observe the relevant job descriptions for body repairs!
1.1. Pierce the membrane in the nozzle connection of components A and B (aluminium cartridge) -H5, H6- with a
screwdriver and enlarge the opening. Remove flanged cover on end of cartridge.
3.2. Insert double cartridge -H5, H6- into the bonding gun -A- .
4.1. By activating the valve -arrow- allow the pressure piston to move out
slowly until both components of the bonding material emerge at the
mixing pipe.
4.2. Wipe off the emerging adhesive.
5.1. Screw processing nozzle -H8- onto the mixing nozzle -H7- .
Note
In this position, the closed surfaces must be visible at the horizontal mixing nozzle from above and below and
the mixing blade of the mixer insert from the sides.
6.2.
7.1. By activating the valve -arrow- allow the pressure piston to move out
slowly until the adhesive is visible in the processing pipe.
Note
In order to ensure that the substance is completely mixed, apply a 30
mm long adhesive bead of fresh adhesive to a piece of cardboard
before processing.
If the contents of the cartridge are not completely used up, the processing nozzle should remain screwed onto
the mixing nozzle. The thoroughly mixed bonding material hardens later in the processing nozzle and seals
the adhesive components from the air. In the event of later processing, a new processing nozzle must then be
used.
8.1.
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Disconnect battery. → 2706IN Work instructions after disconnecting the battery [9PAAD1 9PAAD7]
→ 2706IN Work instructions after disconnecting the battery [9PAAE1 9PAAE7 9PAAF1]→ 2706IN Work
instructions after disconnecting the battery [9PAAJ1]
3. Remove the cardan shaft. → 390219 Removing and installing front cardan shaft - chapter on
"Removing" [9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on
"Removing" [9PAAD1 9PAAD7 9PAAE7]
4. Remove primary catalytic converter. → 267619 Removing and installing primary catalytic converter - chapter
on "Removing" [9PAAE1 9PAAE7]→ 267619 Removing and installing primary catalytic converter - chapter
on "Removing" [9PAAD1 9PAAD7]→ 267619 Removing and installing primary catalytic converter - chapter
on "Removing" [9PAAF1 9PAAJ1]
5. Remove wiper motor. → 921519 Removing and installing wiper motor - chapter on "removing"
6. Remove DME control module. → 247019 Removing and installing DME control module - chapter on
"Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 247019 21 Removing and installing DME
control module - chapter on "Removing" [9PAAJ1]
7. Remove alarm siren. → 966519 Removing and installing alarm siren - chapter on "Removing"
2. Open the retaining clips -arrow A- and take out the DME control
module wire harness -arrow B- .
3. Unscrew the fastening screw -2- and the two fastening nuts -3- and
take out the support for the DME control module.
1. Pull out wire harness retaining clips on the intake manifold -arrow A-
and unclip the wire harness on the intake manifold -arrow B- .
Installation Location:
1. Unclip wire harness -A- in plenum panel and lay it to one side and to the front.
2. Remove left and right heat shield (above the catalytic converters).
2.1. Unscrew fastening nuts and fastening screw -A- on the right and left heat shield.
2.2. Remove left and right heat shield.
DANGER
Left and right heat shield (above the Wire harness in plenum panel
catalytic converters)
Danger of injury!
Wear suitable protective clothing.
Note
After cleaning with isopropanol, a ventilation period of approx. 30 minutes
must always be observed.
Sealing front panel
3. Clean surrounding edge between the firewall plate and the front
panel from the outside, in the area shown -arrows- , at the edge with
cleaning agent (isopropanol).
DANGER
Danger of injury!
Wear suitable protective clothing.
Note
When sealing the firewall plate, ensure without fail that the water drains in the air-conditioning system are not
blocked with sealant.
4. Seal firewall plate from the outside, in the area shown -arrows- , at the edge between the firewall plate and
front panel, all the way round with → Sikaflex-529 body sealant, 000.043.206.36 .
5. Install left and right heat shield (above the catalytic converters).
5.2. Screw on left and right heat shield plate using the fastening nuts and fastening screw -A- on the left and
right heat shield plate.
Wire harness in plenum panel Left and right heat shield (above the
6. Route wire harness -A- in the plenum panel and clip it in. catalytic converters)
1. Position intake manifold and secure with both fastening nuts -1- . →
Tightening torque : 4.5 ftlb.
1. Position support for DME control module and screw down both fastening nuts -3- and the fastening screw -2-
. → Tightening torque: 6 ftlb. → Tightening torque: 6 ftlb.
2. Insert DME control module in the retaining clips -arrow A- and close the retaining clips -arrow B- .
3. Mount ground straps together with the twist lock on the stud and screw down with the fastening nut -1- . →
Tightening torque: 6.5 ftlb.
Subsequent work
Subsequent work
1. Check connection points on main wire harness for corrosion and rework if necessary. → 970949 Reworking
main wire harness - chapter on "Reworking"
2. Install alarm siren. → 966519
Removing and installing alarm
siren - chapter on "Installing"
6. Install cardan shaft. → 390219 Removing and installing front cardan shaft - chapter on "Installing" [9PAAE1
9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on "Installing" [9PAAD1
9PAAD7 9PAAE7]
8. Carry out work instructions after disconnecting the battery. → 2706IN Work instructions after disconnecting
the battery [9PAAD1 9PAAD7]→ 2706IN Work instructions after disconnecting the battery [9PAAE1 9PAAE7
9PAAF1]→ 2706IN Work instructions after disconnecting the battery [9PAAJ1]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1.1. Remove accessories in the repair area according to the extent of damage to the vehicle.
2.1. Equip alignment bench with the basic straightening attachments according to the plans included with the
straightening attachments.
Note
As a result of the joint which seals the side member, the vehicle must not be secured to the straightening
bench with quick-acting claws.
3.1. Position vehicle on straightening bench, align according to the reference holes and bolt firmly with the
straightening set.
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective
covers.
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ → 5000IN General information and notes on quality
Straightening set 9PA Cayenne; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Pneumatic body saw PS1; see Gr. 3.5; Workshop Equipment Manual
Oscillating body saw (special electric cutter); see Gr. 3.5; Workshop Equipment Manual
Hot-air gun Leister Elektron; see Gr. 3.5; Workshop Equipment Manual
Cartridge gun VAG 1628; see Gr. 3.5; Workshop Equipment Manual
Spotweld drill; see Gr. 2.4; Workshop Equipment Manual NR.129 00000
Body sealant from Würth Klebt und Dichtet; see Parts Catalogue; Main Group 8
Installation Location:
Note
All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be
completed before the damaged parts are removed.
1.1. Grind the inert gas arc welding joints between the frame head
(impact absorber mount) and top side member using the parting
grinder → see figure (areas -A- , -B- , -C- , -D- ).
2. Remove frame head (impact absorber mount).
Preparing connection areas of the body for installing the frame head (impact
absorber mount)
Preparing connection areas of body for installing frame head (impact absorber mount)
1. Clean welding and sealing areas.
2.1. Coat all spot-weld flange areas with zinc powder paint.
1.1. Grind both sides of the connection flange of the new parts in the marked areas -F- and -G- until bare using
a rotary brush.
1.1. Position the frame head (impact absorber mount) against the body
and fix in place with a straightening attachment.
1.2. Fix the frame head (impact absorber mount) to the body with
tensioning clamps.
2. Weld the frame head (impact absorber mount) using the inert-gas arc welding process → see figure .
2.1. Apply a full weld to the frame head (impact absorber mount) in the areas -A- , -B- , -C- and -D- using inert-
gas arc welding.
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Removing the front spoiler.
1.1. → 631519 Removing and installing front apron - section on "Removing"
2.1. → 553319 Removing and installing front lid seal - section on "Removing" [9PAAD1 9PAAD7 9PAAE1
9PAAE7]→ 553319 21 Removing and installing front lid seal - section on "Removing" [9PAAF1 9PAAJ1]
3.1. → 700219 Removing and installing front cover (engine compartment) - section on "Removing"
Installation Location:
1. Remove the rubber covers.
ATTENTION
Danger of injury and material damage as a result of incorrect handling of airbag sensors!
Incorrect handling of airbag sensors can result in injury and material damage.
→ Always observe the safety regulations for handling airbag units.→ Safety regulations for handling airbag
and...
→ Remove ignition key. Disconnect battery . Route or isolate the ground strap so that all contact with a ground
carrier (e.g. body, seat frame) is avoided.→ Work instructions after disconnecting the battery.
→ Before the connector is disconnected from the sensor, always wait for 1 minute before disconnecting the
battery.
2.2. Slide the side air guide -15- outwards and remove.
4.1. Screw in service fastening screws on both sides of the vehicle and tighten by hand.
8.1. Disconnect the electrical plug -9- on the left side of the vehicle. Release the lock and disconnect the plug.
Installation Location:
1. Slide the lock mount into its installation position.
1.1. To prevent damage to the accessories, slide the lock mount back
into the installation position on both sides evenly.
2.1. Screw in fastening screws on both sides of the vehicle and tighten slightly.
4.1. Screw in fastening screws on both sides of the vehicle and tighten slightly.
7.1. Tighten fastening screws -3- , -5- , -6 and 7- to the specified tightening torque. → Tightening torque: 6.5
Nm +/-0.5 Nm → Tightening torque: 9 (6.5 ftlb.) Nm +/-1 (0.5 ftlb.) Nm → Tightening torque: 65 (48
ftlb.) Nm +/-10 (7.5 ftlb.) Nm
11.1. Position the side air guide -15- and move it to the centre of the vehicle until it engages.
12.1. → Removing and installing front lid seal [9PAAD1 9PAAD7 9PAAE1 9PAAE7]→ Removing and installing
front lid seal [9PAAF1 9PAAJ1]
13. Connect the electric plug connection -9- .
13.1. Connect the electric plug connection on the left side of the vehicle.
14. Install the rubber covers.
14.1. Put on the right -1- rubber cover from above and press in the
rubber tabs.
Installation Location:
Note
On right-hand drive vehicles, the cable for the lid lock is located on the right side of the vehicle.
Installation Location:
1. Engage the cable and close the connection piece.
1.1. Engage the cable for the front lid lock -13- and close the lid -12- on the connection piece.
Subsequent work
Subsequent work
1. Connect cable for front lid lock.
2.1. Engage the locking hook on the lock in the catch using a screwdriver and trip by actuating the lid release in
the vehicle.
In the case of a malfunction, check the bottom lock section or lid release cable for damage; replace if
necessary.
4.1. → 700219 Removing and installing front cover (engine compartment) - section on "Installing"
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Put lock carrier in service position → 503809 Loosening and fastening the lock carrier (service position) -
chapter on "Loosening".
Installation Location:
1. Unscrewing radiator module
1.1. Remove upper fastening screws -3- on radiator module and secure radiator module -1- onto vehicle to
prevent it from tipping over or falling.
Installation Location:
3.1. Push in plug -7- ( -arrow A- ) until the locking tab -arrow B- is felt
to engage.
3.2. Slide radiator module -1- into the fastening fork on the lock mount.
3.5. Screw in upper fastening screws -3- of radiator module and tighten to the specified tightening torque. →
Tightening torque: 6.5 (4.8 ftlb.) Nm +/-1 (0.5 ftlb.) Nm
Subsequent work
Subsequent work
1. Cayenne Turbo only: Install charge air cooler→ 214323 23 Installing charge air cooler - chapter on
"Installing".
2. Put lock carrier in assembly position → 503809 Loosening and fastening the lock carrier (service position) -
chapter on "Fastening".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1.1. Remove accessories in the repair area according to the extent of damage to the vehicle.
2.1. Equip alignment bench with the basic straightening attachments according to the plans included with the
straightening attachments.
Note
As a result of the joint which seals the side member, the vehicle must not be secured to the straightening
bench with quick-acting claws.
3.1. Position vehicle on straightening bench, align according to the reference holes and bolt firmly with the
straightening set.
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective
covers.
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ → 5000IN General information and notes on quality
Straightening set 9PA Cayenne; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Pneumatic body saw PS1; see Gr. 3.5; Workshop Equipment Manual
Oscillating body saw (special electric cutter); see Gr. 3.5; Workshop Equipment Manual
Hot-air gun Leister Elektron; see Gr. 3.5; Workshop Equipment Manual
Cartridge gun VAG 1628; see Gr. 3.5; Workshop Equipment Manual
Spotweld drill; see Gr. 2.4; Workshop Equipment Manual NR.129 00000
Body sealant from Würth Klebt und Dichtet; see Parts Catalogue; Main Group 8
Installation Location:
Note
All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be
completed before the damaged parts are removed.
1.2. Grind the inert gas arc welding joints between the spring strut mount, top side member, firewall and side
member using the parting grinder (areas -B- , -C- , -F- and -H- ).
2. Remove the spring strut mount.
Preparing connection areas of body for installing spring strut mounts
2.1. Coat all spot-weld flange areas with zinc powder paint.
1.1. Position the spring strut mount against the body and fix in place with a straightened bracket.
1.2. Fix the spring strut mount to the body with tensioning clamps.
2.1. Resistance spot-weld the spring strut mount in areas -D- and -G- .
1.1. Grind both sides of the connection flange of the new parts in the marked areas until bare using a rotary
brush.
1.2. Grind the spring strut mount close to contact surfaces to the new part until bare.
2. Fix bracket for torque support.
2.1. Fix the torque support bracket by assembling the mounting bearer
on the body, aligning it and securing it with tensioning clamps.
4.2. Inert gas arc weld the torque support bracket in area -O- with a full weld.
Subsequent work
Subsequent work for body
repairs
7. Apply cavity preservation to the accessible areas of the repair. → 5000IN Cavity preservation.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
2.1. Open the three plastic clips -4- in the area where the wheel housing
meets the wing.
4.1. Pull servo valve wire harness off the left wheel-housing liner at the
retaining clips -Arrows- .
5.1. Disengage the wheel-housing liner in the area beside the side
direction indicators and in the area where the wheel housing meets
the wing.
Installation Location:
1.2. Screw in fastening screws -6- between connecting piece and front
apron and tighten to specified tightening torque. → Tightening
torque: 2.5 (2.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm .
3.1. Route servo valve wire harness and push it onto the left wheel-
housing liner using the retaining clips -Arrows- .
5.1. In the transition area beside the wing, close the three plastic straps
-4- , screw in the corresponding fastening screws -2- and tighten
slightly.
6.1. Screw in the remaining fastening screws -2- and tighten slightly.
6.2. Check wheel-housing liner
-1- in the area of the side
direction indicator and along
the wheel housing to make
sure that it is correctly
seated.
6.3. Tighten all fastening points
-2- , -3- and -5- to specified
tightening torque →
Tightening torque: 1.5 (1.0
ftlb.) Nm +/-0.5 (0.5 ftlb.)
Nm → Tightening torque:
1.5 (1.0 ftlb.) Nm +/-0.5 (0.5
ftlb.) Nm → Tightening
torque: 2.5 (2.0 ftlb.) Nm
+/-0.5 (0.5 ftlb.) Nm .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1.1. Remove accessories in the repair area according to the extent of damage to the vehicle.
2.1. Equip alignment bench with the basic straightening attachments according to the plans included with the
straightening attachments.
Note
As a result of the joint which seals the side member, the vehicle must not be secured to the straightening
bench with quick-acting claws.
3.1. Position vehicle on straightening bench, align according to the reference holes and bolt firmly with the
straightening set.
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective
covers.
5. Reshape connection area of the sheetmetal parts to be replaced.
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
DANGER
Risk of damage and injury if the safety instructions for body repairs are not observed.
Ignoring the safety instructions for body repairs can result in material damage and injury.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ → 5000IN General information and notes on quality
Straightening set 9PA Cayenne; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Pneumatic body saw PS1; see Gr. 3.5; Workshop Equipment Manual
Oscillating body saw (special electric cutter); see Gr. 3.5; Workshop Equipment Manual
Hot-air gun Leister Elektron; see Gr. 3.5; Workshop Equipment Manual
Cartridge gun VAG 1628; see Gr. 3.5; Workshop Equipment Manual
Spotweld drill; see Gr. 2.4; Workshop Equipment Manual NR.129 00000
Body sealant from Würth Klebt und Dichtet; see Parts Catalogue; Main Group 8
Installation Location:
1. Separating the side member for the wheel housing upper section
from the wing mounting point support
1.1. Cut the welded joint between the wing mounting point support and side member bracket using the spotweld
cutter (areas -A- ).
1.2. Grind the inert gas arc welded joint between the wing mounting
point support and front side member and side member bracket with
a parting grinder (areas -B- , -C- ).
1.3. Cut out the laser welded joint on the side member for the wheel housing upper section in the area of the
cut offset -X- using the parting grinder (area -D- ).
1.4. Cut the side member for the wheel housing upper section in the areas -E- and -F- using the oscillating body
saw. The dimension -X- (or -X- ) → Cut dimension, old part: 80 mm must be maintained. Do not damage
the internal components.
2. Removing side member for wheel housing upper section
Preparing connection areas of body for installing side member for wheel housing
upper section
Preparing connection areas of body for installing wheel housing upper section side member
2.1. Coat all spot-weld flange areas with zinc powder paint.
Preparing side member for installing wheel housing upper section
4.1. Coat all spot-weld flange areas (areas -A- , -D- or -D- ) with zinc powder paint.
Fitting side member for wheel housing upper section
1. Fit the side member for the wheel housing upper section to the body.
1.1. Fix the wing mounting point support to the body with the attachment set.
1.2. Place the side member for the wheel housing upper section (inner part) on the body and fix in place with
the straightening bracket. Fix the side member for the wheel housing upper section (inner part) to the
remaining piece on the body using tensioning clamps.
1.3. In the area of the overlap of the side member for the wheel housing
upper section (inner part) and body, cut the two sheetmetal plates
with a cut -W- (or -W- ) using the oscillating body saw. Do not
damage the internal components.
1.4. Place the side member for the wheel housing upper section (outer
part) on the body and fix in place with the straightening bracket. Fix
the side member for the wheel housing upper section (outer part) to
the remaining piece on the body using tensioning clamps.
1.5. In the area of the overlap of the side member for the wheel housing
upper section (outer part) and body, cut the two sheetmetal plates
with a cut -W- (or -W- ) using the oscillating body saw. Do not
damage the internal components.
2.3. Grind both sides of the welding areas in the area of the cuts on the
body and new parts until bare using a rotary brush.
3.1. Touch up the spot-weld flange areas of the overlap with zinc
powder paint.
1. Fix the side member for the wheel housing upper section to the body.
1.1. Place the side member for the wheel housing upper section (inner and outer part) on the body and fix in
place with the straightening bracket. Fix the side member for the wheel housing upper section to the
remaining piece on the body using tensioning clamps.
2. Resistance spot-weld the support for the wing mounting point and
side member for wheel housing upper section.
2.1. Resistance spot-weld the support for the wing mounting point and
side member for wheel housing upper section in the areas -A- , -D-
and -G- .
3. Weld support for the wing mounting point and side member for wheel
housing upper section under shielding gas.
3.1. MIG weld the side member for wheel housing upper section in the
areas -E- , -F- and -C- with a full weld. Plug-weld the support for the
wing mounting point in the area -I- , -J- under shielding gas. MIG
weld the support for the wing mounting point in the area -B- , -H-
with an intermittent weld.
Subsequent work
7. Apply cavity preservation to the accessible areas of the repair. → 5000IN Cavity preservation.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1.1. Remove accessories in the repair area according to the extent of damage to the vehicle.
2.1. Equip alignment bench with the basic straightening attachments according to the plans included with the
straightening attachments.
Note
As a result of the joint which seals the side member, the vehicle must not be secured to the straightening
bench with quick-acting claws.
3.1. Position vehicle on straightening bench, align according to the reference holes and bolt firmly with the
straightening set.
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective
covers.
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ → 5000IN General information and notes on quality
Straightening set 9PA Cayenne; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Pneumatic body saw PS1; see Gr. 3.5; Workshop Equipment Manual
Oscillating body saw (special electric cutter); see Gr. 3.5; Workshop Equipment Manual
Hot-air gun Leister Elektron; see Gr. 3.5; Workshop Equipment Manual
Cartridge gun VAG 1628; see Gr. 3.5; Workshop Equipment Manual
Spotweld drill; see Gr. 2.4; Workshop Equipment Manual NR.129 00000
Body sealant from Würth Klebt und Dichtet; see Parts Catalogue; Main Group 8
Note
All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be
completed before the damaged parts are removed.
Installation Location:
1. Cut off side member for wheel housing upper inner section.
2.1. Cut out the laser welded joint on the side member for the wheel
housing upper section in the area of the cut offset -X2- using the
parting grinder (area -A1- ).
3.1. Mill off the welded joints in area -A, D- using a spotweld cutter.
11.1. Using a parting grinder, separate the bracket on the side member in
the area -N- .
13.1. Mill off the welded joints in area -P- and -U- using a spotweld
cutter.
14.1. In area -R- cut out a lid from the floor with a parting grinder.
14.2. Mill off the welded joints in area -S- using a spotweld cutter.
Installation Location:
Separating welded joints at the web Cutting out a lid in the floor
plate
15.1. Mill off the welded joints in area -V- using a spotweld cutter.
16.1. Mill off the welded joints in area -Y- , -Y- and -Y- using a spotweld
cutter.
16.2. Grind off the welded joints in area -Z- and -Z- using a parting grinder.
Installation Location:
1. Prepare connection areas of spring strut mount for installation.
Installation Location:
1. Prepare side member in area of bracket for installation.
2.1. Grind both sides of the connection flanges of the new part in the
marked areas -B- until bare using a rotary brush.
5.1. Grind both sides of the connection flanges of the new part in the
marked areas -E, F- until bare using a rotary brush.
6.1. Grind both sides of the connection flanges of the new part in the
marked areas -G, H- until bare using a rotary brush.
7.1. Grind both sides of the connection flanges of the new part in the
marked areas -I- until bare using a rotary brush.
8.1. Grind both sides of the connection flanges of the new part in the
marked areas -L, K- until bare using a rotary brush.
1.1. Place the side member against the body and fasten to the
straightening set.
Note
To fit the side member, the frame head (impact absorber mount) and
the top side member support must be secured to the straightening
attachments.
1.2. Install frame head and support for top side member.
Preparing reinforcement for installation
Installation Location:
2.1. Plug-weld the side member in area -S- under shielding gas.
2.2. Weld the side member in area -T- with interrupted full weld under
shielding gas.
4.1. Plug-weld the spring strut mount in area -A- under shielding gas.
4.2. Weld the spring strut mount in area -B, C- with interrupted full weld
under shielding gas.
8.1. Plug-weld the side member in area -P- and -U- under shielding gas.
Installation Location:
9.1. Plug-weld the side member in area -V- under shielding gas.
Installation Location:
Welded joints at bottom of side Welded joints at bottom of side
member member
10.1. Plug-weld the side member in area -Y- , -Y- and -Y- under shielding
gas.
10.2. Weld the side member in area -Z- and -Z- with interrupted full weld under shielding gas.
Welded joints at firewall lower section
13.4. Position the reinforcement and plug-weld in area -R- under shielding gas.
7. Apply cavity preservation to the accessible areas of the repair. → 5000IN Cavity preservation.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work for body repairs with alignment bench
1. Removing accessories in the repair area.
1.1. Remove accessories in the repair area according to the extent of damage to the vehicle.
2.1. Equip alignment bench with the basic straightening attachments according to the plans included with the
straightening attachments.
Note
As a result of the joint which seals the side member, the vehicle must not be secured to the straightening
bench with quick-acting claws.
3.1. Position vehicle on straightening bench, align according to the reference holes and bolt firmly with the
straightening set.
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective
covers.
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
DANGER
Risk of damage and injury if the safety instructions for body repairs are not observed.
Ignoring the safety instructions for body repairs can result in material damage and injury.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ → 5000IN General information and notes on quality
Straightening set 9PA Cayenne; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Pneumatic body saw PS1; see Gr. 3.5; Workshop Equipment Manual
Oscillating body saw (special electric cutter); see Gr. 3.5; Workshop Equipment Manual
Hot-air gun Leister Elektron; see Gr. 3.5; Workshop Equipment Manual
Cartridge gun VAG 1628; see Gr. 3.5; Workshop Equipment Manual
Spotweld drill; see Gr. 2.4; Workshop Equipment Manual NR.129 00000
Body sealant from Würth Klebt und Dichtet; see Parts Catalogue; Main Group 8
Note
All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be
completed before the damaged parts are removed.
1.1.
1.2. Cut the welded joint between the wing mounting point support and
the side member for the wheel housing upper section using the
spotweld cutter (areas -A- , -B- ).
1.3. Cut through the side member area -C- using an angle grinder. Use 1 mm cutting discs for high-strength
steel NR.129-1 for cutting. The dimension -X- must be maintained. → Cut dimension, old part: 400 mm
2. Remove side member.
Note
Thick body panels (> 1.5 mm) must not be butt-welded without a welding gap.
Always allow a welding gap of s = approx. 1x material strength when fitting new parts.
1.1. Fix inner side member -1- to frame head and secure support for
upper side member.
1.2. Mark the cut -D- in the area where the inner side member overlaps.
1.3. Fix inner side member -1- to frame head and secure support for upper side member.
1.4. Grind off the MIG welded joints on the outer side member in the area -G- using a parting grinder.
1.6. Mark the cut -E- in the area where the outer side member overlaps.
1.7. Mill off the welded joints in area -F- using the spotweld cutter.
1.8. Remove new part and cut
remaining piece on the
body. Allow for welding gap
→ Welding gap: 2 mm and
do not damage internal
components!
WARNING
Risk of material damage and personal injury if body repair work is not carried out correctly.
On vehicles that have not been repaired correctly, an accident in the repair area can result in the
unintentional triggering of airbags and belt tensioners. As a result, optimal passenger safety can no
longer be assured.
→ Resistance spot welding on the side member may only be carried out using the welders approved in the
Workshop Equipment Manual: ATL InvertaSpot we1194 and MULTISPOT MI-100 we1208.
→ Set the welding parameters to the required thickness (approx. 2.5) and power (approx. 9000A).
→ Observe a point distance with regard to the original joint.
→ Thick body panels (> 1.5 mm) must not be butt-welded without a welding gap during inert-gas arc welding.
→ To achieve the required welding quality, maintain a welding gap of s = approx. 1x material strength.
→ Do not grind weld seams.
1.1. Fix side member to frame head and secure support for side member.
1.2. Fix the side member to the body using tensioning clamps.
2.1. Use an inert-gas arc welder to weld the inner side member in area
-J- to the inside of the carrier with a full weld.
3.1. Plug-weld the outer side member in area -S- under shielding gas.
3.2. MIG weld the outer side member with a full weld in area -K- , -L- ,
-M and N- .
4.1. Fix outer side member to inner side member using tensioning
clamps.
4.2. Resistance spot-weld the side member in areas -O, P, Q- and -R- .
5.1. The procedure is described in → Replacing side member for wheel housing upper section.
Subsequent work
7. Apply cavity preservation to the accessible areas of the repair. → 5000IN Cavity preservation.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
DANGER
Risk of damage and injury if the safety instructions for body repairs are not observed.
Ignoring the safety instructions for body repairs can result in material damage and injury.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→
Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ → 5000IN General information and notes on quality
Cartridge gun V.A.G 1628 - see Workshop Equipment Manual, Chapter 3.5
Body sealant "Klebt und Dichtet" from Würth, see Parts Catalogue, Main Group 8
Installation Location:
1.1. Place driver's seat in service position. → 270619 Removing and installing battery [9PAAE1 9PAAE7
9PAAF1]→ 270619 Removing and installing battery [9PAAJ1]→ 270619 Removing and installing
battery [9PAAD1 9PAAD7]
2.1. Remove undersealing, paint, etc. from the welding areas of the body on upper and lower sides with a hot-
air gun or rotary brush.
12.1. → Undersealing
14.1. → Remove main switch for power supply (battery disconnect switch) [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Remove main switch for power supply (battery disconnect switch) [9PAAJ1]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Note
If it can be ensured there has been no deformation of the vehicle structure, the following repair can be carried
out without the need of a straightening bench. In this case, the vehicle must not be raised when welding the
component; it must stand on its wheels on an even surface.
1.1. Remove accessories in the repair area according to the extent of damage on the vehicle.
2.1. Set up straightening bench with the straightening set according to the set-up drawings included with the
straightening set.
Note
As a result of the joint which seals the side member, the vehicle must not be secured to the straightening
bench with quick-acting claws.
3.1. Position vehicle on straightening bench, align to the reference holes and firmly bolt using the straightening
set..
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective covers.
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
General warning notes
DANGER
Risk of damage and injury if the safety instructions for body repairs are not observed.
Ignoring the safety instructions for body repairs can result in material damage and injury.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ → 5000IN General information and notes on quality
Straightening set 9PA Cayenne; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Pneumatic body saw PS1; see Gr. 3.5; Workshop Equipment Manual
Oscillating body saw (special electric cutter); see Gr. 3.5; Workshop Equipment Manual
Hot-air gun Leister Elektron; see Gr. 3.5; Workshop Equipment Manual
Cartridge gun VAG 1628; see Gr. 3.5; Workshop Equipment Manual
Spotweld drill; see Gr. 2.4; Workshop Equipment Manual NR.129 00000
Removing roof
Removing roof
Installation Location:
1. Mill off the spot welds in the front and side roof areas.
1.1. Mill off the spot welds of the front roof cross member -A- and in the
area of the roof strips -B- using a spotweld cutter.
2.1. Cut off the roof with the oscillating body saw in the area -C- on both
sides.
3. Mill off the spot welds in the rear roof area.
3.1. Mill off the spot welds in the rear roof area -D- and in the area of the
hinge mounting -E- .
4.1. Heat roof bonding in area of the cross members -F- and -G- using a
hot-air gun.
Note
During separation make sure that the components beneath are not
damaged.
5.1. Cut off laser soldered joints on side panels (areas -H- ).
1.1. Separate metal inert-gas welds -L- between roof and roof frame with
an angle grinder.
Note
It must be possible to fit the roof without tension. There should be a
uniform gap with the side panels of approx. 0.5 - 1 mm on both sides.
3.1. Place roof on roof frame at front and swivel in towards the rear..
5.1. MIG weld both side panels at the separated connection points to the roof frame -M- with a full weld.
6.1. Clean the body connection flanges of paint in the marked areas using a hot-air gun. Grind the connection
flanges until bare.
Note
Keep welding and bonding areas at connection points free of paint.
6.2. If necessary, touch up any paint damage in areas that will later no longer be accessible.
Note
Leave cleaned areas to dry for approx. 1 - 2 minutes. Bonding areas must be completely dry.
Ensure that clean gloves are
worn when touching cleaned
surfaces to avoid transferring
sweat from the hands and dirt
onto the bonding areas.
Note
The spacers are delivered as sub-parts. Individual pieces must be cut
to a width of approx.8 mm and affixed for the assembly.
9.2. Stick spacers on the roof support of the side panels approx. 150 mm
apart.
10.1. Coat spot-weld flange areas inside roof frame and roof cross members with zinc powder paint..
1.1. Grind bare the welding flanges in area of front roof cross member
-A- and in area of roof strips -B- using a rotary brush.
3.2. On the inside of the roof, grind bare the adhesive flanges in area of hinge mountings -E- using grain 150
sandpaper.
Note
Do not apply zinc powder paint to the bonding areas -I- .
4.1. Coat all spot-weld flange areas with zinc powder paint -A, B-
Note
Do not apply zinc powder paint to the bonding areas -E- .
5.1. Coat spot-weld flange area -D- with zinc powder paint.
Installing roof
Installing roof
ATTENTION
Danger of poisoning and injury when handling adhesive!
Danger of poisoning from breathing in vapours or from swallowing adhesive.
Risk of injury due to contact with skin or eyes.
→ Ventilate the work area well.
→ Do not eat, drink, or smoke while carrying out work.
→ Avoid direct contact with eyes and skin. Wear suitable protective equipment, such as protective clothing,
gloves, and if necessary, a protective mask.
→ If clothing is soiled with adhesive, change clothing immediately and only use again after they have been
cleaned.
→ Also observe the product-specific processing and safety instructions on the packing container and packing
container imprints.
→ In case of eye contact: Rinse eyes immediately and thoroughly with lukewarm running water and consult an
eye doctor.
→ In case of skin contact: Rinse contacted skin areas immediately with lukewarm running water and soap.
→ If adhesive is swallowed: Rinse mouth and consult a doctor.
Note
Minimum ambient and material temperatures during working and hardening → Working temperature: 18
deg. Celsius .
Areas not treated with cathodic immersion painting and exposed body panels must be brushed or filled with
structural adhesive.
Note
Bonding in the roof requires two people.
Do not begin bonding work until all materials and tools necessary for later repair work are available. The roof
bonding process can only be carried out reliably when a smooth and swift sequence of operations is
guaranteed.
Before final assembly, make sure you fully understand all the work steps involved and carry out a trial
assembly without application of adhesive.
In addition to this instruction, also observe the general information for working with body structural adhesive
→ 501000 Working with body structural adhesive.
1. Glue on spacers.
Note
To avoid undesirable displacement of the adhesive, two spacers must
be put in place on the front roof cross member before placing the roof
panel.
1.1.
Fix two spacers with adhesive tape on the front cross member so that they project beyond the front edge of
the roof and can later be easily withdrawn from the gap.
1.2. Before assembling the roof, clean the adhesive flanges once more with acetone and leave to dry off for
approx. 1 – 2 min.
2.1. Apply Würth Klebt und Dichtet body sealant to the roof cross
members in the area of the bond with the roof outer panel using a
bead height of → Application depth: 15 mm .
3.1. Apply structural adhesive Terokal 5045 to the roof outer edge and on
the inside of the roof panel in the area of the hinge connection points
and spread evenly with a brush or a wooden spatula.
4. Apply structural adhesive to the hinge mountings.
Note
The exposed sheetmetal areas must be completely coated with an even
adhesive film of → Application depth: 1 mm .
Note
The exposed sheetmetal areas must be completely coated with an even
adhesive film of → Application depth: 1 mm .
5.1. Apply structural adhesive Terokal 5045 to the side panels and spread evenly with a brush -Arrows- .
5.2. Additionally, in the area of the contact surface, apply structural adhesive with a bead height -X- →
Application depth: 8 mm .
6. Position roof.
6.1. Place roof on roof frame at front and swivel in towards the rear.
7. Remove spacers.
7.1. Remove spacers completely on both sides.
8. Align roof.
9. Align roof.
9.1. Position roof panel in the roof channel at front and rear and at the hinge connection points using a suitable
round material (drift) and check for correct installation position.
Note
By placing styropore pads or similar material under the tension straps, the tension can be increased at the
points required.
The tensioning straps must remain on the vehicle until hardening of the structural adhesive is complete.
10.2. Fit tensioning straps to the outer surfaces of the roof and clamp the roof.
11.1. Remove most of the excess adhesive material with paper or cloth.
Note
Have this work carried out by an assistant whilst at the same time starting with the welding work.
12.1. Spot weld roof in area of front roof cross member -A- and at the roof
frame connection points -B- .
12.3. MIG weld roof in area of rear side panels -E- with full weld.
Note
The body structural adhesive
used hardens at room
temperature.
Information on accelerated
hardening can be obtained Illustration without tensioning straps Illustration without tensioning straps
from → 5000IN Working with
body structural adhesive.
Note
After repairs with adhesive, allow at least ten hours before moving or carrying out further work on the vehicle
(leave standing overnight) to avoid damage to the bonded joint by premature loading.
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Note
If it can be ensured there has been no deformation of the vehicle structure, the following repair can be carried
out without the need of a straightening bench. In this case, the vehicle must not be raised when welding the
component; it must stand on its wheels on an even surface.
1.1. Remove accessories in the repair area according to the extent of damage on the vehicle.
Note
As a result of the joint which seals the side member, the vehicle must not be secured to the straightening
bench with quick-acting claws.
3.1. Position vehicle on straightening bench, align to the reference holes and firmly bolt using the straightening
set..
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective covers.
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
DANGER
Risk of damage and injury if the safety instructions for body repairs are not observed.
Ignoring the safety instructions for body repairs can result in material damage and injury.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→
Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ → 5000IN General information and notes on quality
Straightening set 9PA Cayenne; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Pneumatic body saw PS1; see Gr. 3.5; Workshop Equipment Manual
Oscillating body saw (special electric cutter); see Gr. 3.5; Workshop Equipment Manual
Hot-air gun Leister Elektron; see Gr. 3.5; Workshop Equipment Manual
Cartridge gun VAG 1628; see Gr. 3.5; Workshop Equipment Manual
Spotweld drill; see Gr. 2.4; Workshop Equipment Manual NR.129 00000
Body sealant from Würth Klebt und Dichtet; see Parts Catalogue; Main Group 8
Technical values
Gap dimensions
Note
The figures showing the gap dimensions can be found in the section entitled → Diagram of gap dimensions.
Installation Location:
Note
All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be
completed before the damaged parts are removed.
1.3. Mill off the welded joint on the lower side member using the spotweld cutter (areas -D- , -E- , -K- ,
-I and J- ).
2.1. In series production, the lower side member is sealed in the area of the pillars and wheel arch with
expanded foam sealing parts. These seals are destroyed when the lower side member is removed and must
be replaced when the member is reinstalled.
3. Shorten wing fastening rail.
3.2. Mill off the welded joint on the remaining piece of the fastening rail using the spotweld cutter.
3.3. Remove the remaining piece of the fastening rail.
Preparing
Installation Location:
1. Produce repair part.
1.1. Cut off the connection areas to the pillar on the new lower side
member. Ensure that the repair part in the area of the cut overlaps
by -W- → Overlap: 50 mm over the remaining piece of the vehicle.
The overlap on the wheel arch is automatically defined when the cut
is made.
Installation Location:
2.1. Fix the lower side member to the body with tensioning clamps. To fit, install the front and rear doors and
adjust the contours and gap dimensions between the doors and lower side member according to the
adjustment values.
→ Gap dimensions
3.1. Use a body saw to cut the two sheetmetal plates -T- in the area of the overlap between the lower side
member and pillars. Do not damage the internal components.
4.1. Remove lower side member and remaining pieces from the pillars.
5.1. Grind both sides of the connection flange of the lower side member in the marked areas -A- ,
-B, C, D, E, I, J- , -F- , -G, H- and -K- until bare using a rotary brush.
6. Drilling holes for plug welding using inert gas
Installing seals
Installation Location:
1.2. Place the seal against the body and press into place -arrows- .
Installation Location:
2. Install lower B-pillar seal -2- .
2.2. Place the seal against the body and press into place -arrows- .
Installation Location:
3. Install lower C-pillar seal -3- .
3.2. Place the seal against the body and press into place -arrows- .
3.3. On the seal , apply body sealing compound Würth Klebt und
Dichtet -5- . Maintain the application depth -V- → Application
depth: 10 mm .
ATTENTION
Risk of damage if the processing time for the body adhesive sealant is not observed.
The binding quality is affected if the processing time is not observed.
→ Observe the processing time of the body adhesive sealant (No. 1)!
→
The new part must be welded within 30 minutes in the area of the adhesive, otherwise the binding quality is
affected.
1.2. Apply -M- Teromix-6700 two-component adhesive thinly at the door hinge flange area.
2.1. Fit lower side member to the body. Adjust the contours and gap dimensions according to the previous fitting
process. Fix the lower side member with tensioning clamps.
3.1. Resistance spot-weld the lower side member in areas -A- , -B, C, E-
, -I- and -K- .
Note
In the case of the Cayenne Turbo, the undersealing in the area of the outer lower side member is painted in the
colour of the vehicle. This means that after priming the repair area on these vehicles, undersealing must also be
applied to this area.
4.2. Cut the two sheetmetal plates -T- using the oscillating body saw in
the area of the overlap with the fastening rail. Do not damage the
internal components when doing this.
5.3. Grind down both sides of the welding areas in the area of the cuts on
the body and new part with a rotary brush.
6. Welding in the wing fastening rail
6.1. Plug-weld the wing fastening rail in area -N- under shielding gas.
Inert gas arc weld the wing fastening rail in area -M- with a full weld.
Subsequent work
7. Apply cavity preservation to the accessible areas of the repair. → 5000IN Cavity preservation.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1.1. Remove accessories in the repair area according to the extent of damage to the vehicle.
2.1. Equip alignment bench with the basic straightening attachments according to the plans included with the
straightening attachments.
Note
As a result of the joint which seals the side member, the vehicle must not be secured to the straightening
bench with quick-acting claws.
3.1. Position vehicle on straightening bench, align according to the reference holes and bolt firmly with the
straightening set.
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective
covers.
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ → 5000IN General information and notes on quality
Straightening set 9PA Cayenne; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Pneumatic body saw PS1; see Gr. 3.5; Workshop Equipment Manual
Oscillating body saw (special electric cutter); see Gr. 3.5; Workshop Equipment Manual
Hot-air gun Leister Elektron; see Gr. 3.5; Workshop Equipment Manual
Cartridge gun VAG 1628; see Gr. 3.5; Workshop Equipment Manual
Spotweld drill; see Gr. 2.4; Workshop Equipment Manual NR.129 00000
Body sealant from Würth Klebt und Dichtet; see Parts Catalogue; Main Group 8
Installation Location:
Note
All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be
completed before the damaged parts are removed.
2. Mill off the lower side member reinforcement in the area of the pillars.
Installation Location:
Installation Location:
Installation Location:
3. Remove lower side member reinforcement.
Preparing connection area of body for installing lower side member reinforcement
1. Clean welding and sealing areas.
1.1. Clean the body connection flange of undersealing and paint in the marked areas using a hot-air gun or
Installation Location:
Installation Location:
Installation Location:
Fitting outer lower side member reinforcement and preparing for installation
Fitting outer lower side member reinforcement and preparing for installation
Installation Location:
1. Drill holes for plug welding using inert gas.
1.1. Drill holes with ø = 7 mm -A- , -B- , -C- in the fastening flanges of the lower side member reinforcement.
2.1. Grind both sides of the connection flange of the lower side member in the marked areas until bare using a
rotary brush.
Installation Location:
1. Fit lower side member reinforcement to the body.
1.1. Fit the lower side member reinforcement to the body and secure with tensioning clips. When fitting, align
the reference holes of the lower side member reinforcement and pillar reinforcement -arrow- .
Subsequent work
7. Apply cavity preservation to the accessible areas of the repair. → 5000IN Cavity preservation.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
1.1. Remove accessories in the repair area according to the extent of damage on the vehicle.
2. Covering the accessories adjacent to the area of the vehicle requiring repair.
2.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective
covers.
3.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
Item Designation
1 MIG welder
2 Angle grinder
3 Hot-air gun leister-electron
4 Rotary brush
5 Conical shell reaming drill NR.128
6 Spotweld drill NR.129
7 Body sealant "Klebt und Dichtet" from Würth
8 Threaded bushing
9 Plug ø 30 mm
Technical values
Designation Dimension Note
Diameter of outlet hole -x- 30 mm
Installation Location:
1.1. On the extension of the seat cross member, use a conical shell reaming drill NR.128 to bore out the
diameter of the drain hole to the dimension -A- = 30 mm.
3.1. Drill out a connection between the seat cross member and the threaded insert using a spotweld cutter
NR.129.
4. Removing threaded bush.
Installation Location:
1. Preparing the threaded bush for installation
1.1. Grind the threaded bush -1- bright on the contact surface with the seat cross member.
2.1. Insert a new threaded bush -1- fully into the seat cross member from below.
2.3. Insert an M8 x 120 bolt -2- into the seat cross member from above.
2.4. Screw the bolt -2- approx. three revolutions into the threaded bush -1- .
2.5. Pull the threaded bush -1- with the screw -2- up to the seat cross member.
4.1. Unscrew the bolt and grind the spot welds flat.
9.1. Close the drain hole by inserting a 30-mm diameter plug -3- from
below.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Note
To mill the required shoulder, the tool with the designation Spot facer for Time-Sert thread repair set
NR.122-2 must be used. The tool provided with the complete set supplied must not be used in this case!
Installation Location:
Installation Location:
Note
The repair bush must be installed recessed. To mill the required shoulder, the tool with the designation Spot
facer for Time-Sert thread repair set NR.122-2 must be used. The tool provided with the complete set
supplied must not be used in this case!
1.1. Drill out the old thread with a drill to the root of the thread.
2. Mill shoulder.
2.1. Mill out drill hole with spot facer -C- to dimension -X- . → Test and adjustment value: 10 mm Milling must
only be performed using tool Spot facer for Time-Sert thread repair set NR.122-2!
For milling, use an electronically controlled power drill set at a speed of approx. 250 1 /min.
3. Cut thread.
3.1. Cut thread using a cutting tool -D- up to dimension -Y- in the chassis bushing. → Test and adjustment
value: 40 mm Clean thread on chassis bushing (blow out swarf).
4.3. Screw the threaded bush -A- onto the screw-in tool -E- by hand.
Note
While pressing in the base thread, a noticeably larger amount of force
on the screw-in tool is required to form the internal thread. Pressing is
finished when the screw-in tool can be turned further more easily.
6. Press threaded bush.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
Installation Location:
2. Remove cover.
Installation Location:
3. Remove middle cover.
3.2. Remove centre cover -4- in the rear area downwards from the body ( -Arrow D- ).
3.3. Pull out middle cover -4- in the front area under the wheel housing liner -6- ( -Arrow E- ).
3.4. Take off the middle cover.
Installation Location:
1. Installing middle cover
1.1. Insert middle cover -4- in the front area under the wheel housing
liner -6- and push it forward ( -Arrow A- ).
1.2. Place centre cover -4- on the body -Arrow B- and position it.
1.3. Screw in fastening screws -5- and tighten to the specified tightening
torque → Tightening torque: 1.9 (1.5 ftlb.) Nm +/-0.14 (0.10 ftlb.)
Nm
Installation Location:
2. Install cover.
Installation Location:
3. Install lifting platform holder.
3.1. Place lifting platform holder -2- on the body -Arrow E- and position
it.
3.2. Screw in fastening screws -1- and tighten to the specified tightening
torque → Tightening torque: 9 (6.5 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Note
If it can be ensured there has been no deformation of the vehicle structure, the following repair can be carried
out without the need of a straightening bench. In this case, the vehicle must not be raised when welding the
component; it must stand on its wheels on an even surface.
1.1. Remove accessories in the repair area according to the extent of damage on the vehicle.
2.1. Set up straightening bench with the straightening set according to the set-up drawings included with the
straightening set.
Note
As a result of the joint which seals the side member, the vehicle must not be secured to the straightening
bench with quick-acting claws.
3.1. Position vehicle on straightening bench, align to the reference holes and firmly bolt using the straightening
set..
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective covers.
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
General warning notes
DANGER
Risk of damage and injury if the safety instructions for body repairs are not observed.
Ignoring the safety instructions for body repairs can result in material damage and injury.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ → 5000IN General information and notes on quality
Straightening set 9PA Cayenne; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Pneumatic body saw PS1; see Gr. 3.5; Workshop Equipment Manual
Oscillating body saw (special electric cutter); see Gr. 3.5; Workshop Equipment Manual
Hot-air gun Leister Elektron; see Gr. 3.5; Workshop Equipment Manual
Cartridge gun VAG 1628; see Gr. 3.5; Workshop Equipment Manual
Spotweld drill; see Gr. 2.4; Workshop Equipment Manual NR.129 00000
Body sealant from Würth Klebt und Dichtet; see Parts Catalogue; Main Group 8
Abschlussblech ausbauen
Installation Location:
Note
All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be
completed before the damaged parts are removed.
Installation Location:
Installation Location:
Installation Location:
Preparing
Installation Location:
1. Clean welding and sealing areas.
1.1. Clean the body connection flanges of undersealing, adhesive
residue and paint in the marked areas using a hot-air gun or rotary
brush. Grind the connection flange until bare.
2. Coat spot-weld flange areas
with zinc powder paint.
Installation Location:
2.1. Coat all spot-weld flange areas with zinc powder paint (areas -A, B- , -C, D- ).
Installing end plate
Installation Location:
1. Fit the closing panel to the body.
1.1. Position the closing panel on the body and fix in place with tensioning clamps. Ensure that the closing panel
is positioned flat at the connection point for the bumper.
3.1. Inset gas arc weld the closing panel in the area -E- ( -E- ) with a full weld.
Subsequent work
7. Apply cavity preservation to the accessible areas of the repair. → 5000IN Cavity preservation.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Note
If it can be ensured there has been no deformation of the vehicle structure, the following repair can be carried
out without the need of a straightening bench. In this case, the vehicle must not be raised when welding the
component; it must stand on its wheels on an even surface.
1.1. Remove accessories in the repair area according to the extent of damage on the vehicle.
Note
As a result of the joint which seals the side member, the vehicle must not be secured to the straightening
bench with quick-acting claws.
3.1. Position vehicle on straightening bench, align to the reference holes and firmly bolt using the straightening
set..
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective covers.
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
DANGER
Risk of damage and injury if the safety instructions for body repairs are not observed.
Ignoring the safety instructions for body repairs can result in material damage and injury.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→
Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ → 5000IN General information and notes on quality
Straightening set 9PA Cayenne; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Pneumatic body saw PS1; see Gr. 3.5; Workshop Equipment Manual
Oscillating body saw (special electric cutter); see Gr. 3.5; Workshop Equipment Manual
Hot-air gun Leister Elektron; see Gr. 3.5; Workshop Equipment Manual
Cartridge gun VAG 1628; see Gr. 3.5; Workshop Equipment Manual
Spotweld drill; see Gr. 2.4; Workshop Equipment Manual NR.129 00000
Body sealant from Würth Klebt und Dichtet; see Parts Catalogue; Main Group 8
Technical values
Gap dimensions
Note
The figures showing the gap dimensions can be found in the section entitled → Diagram of gap dimensions.
Installation Location:
Note
All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be
completed before the damaged parts are removed.
1.1. Cut through the side panel in the areas -C- , -D- and -E- using the oscillating body saw. Maintain the
dimensions -X- → Cut dimension, old part: 220 mm , -Y- → Cut dimension, old part: 200 mm and -Z- →
Cut dimension, old part: 150 mm . Do not damage internal components.
1.3. Cut the laser-welded joint
between the rear side panel
and reinforcement on the C-
pillar using the parting grinder
(area -A- ).
Preparing
Installation Location:
2.1. Coat all spot-weld flange areas on which there is no body adhesive
with zinc powder paint.
Note
As a result of technical issues, it is not possible to provide a side section with a tail light holder with hole
pattern for repair work. In this case, a specially developed, adjustable
retainer plate is available which must also be installed.
2.1. Grind both sides of the connection flange of the side panel in the
marked areas -A, B, F, G- and -H, I- ( -I- ) until bare using a rotary
brush.
3.1. On the fastening flange in area -H- of the rear side panel, bore holes ø = 7 mm or punch them using a hole
punch. Maintain spacing between the bores as on the old part.
Installation Location:
Note
When fitting the side section using the alignment bench, the side portal can also be used.
1.1. To complete the fit, install the rear doors and lid and set the gap dimensions between the rear doors and lid
and the side panel according to the respective adjustment values.
2.1. Use a body saw to cut the two sheetmetal plates in the area of the overlap between the side panel and
body. Do not damage the internal components.
3. Applying body sealant to the wheel housing and in the area of the catch bar
ATTENTION
Risk of damage if the processing time is not observed!
The binding quality of the adhesive (No. 1) is affected if the processing time is not observed!
5.1. Resistance spot weld the side panel in the areas -A, B- ; -F- ; -G- and -I- ( -I- ).
8. Grind inert gas arc weld areas, which are visible following installation, until bare, apply body solder to body
joints and align as required.
Subsequent work
Installation Location:
1. Mark drill holes on the bracket.
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Note
If it can be ensured there has been no deformation of the vehicle structure, the following repair can be carried
out without the need of a straightening bench. In this case, the vehicle must not be raised when welding the
component; it must stand on its wheels on an even surface.
1.1. Remove accessories in the repair area according to the extent of damage on the vehicle.
2.1. Set up straightening bench with the straightening set according to the set-up drawings included with the
straightening set.
Note
As a result of the joint which seals the side member, the vehicle must not be secured to the straightening
bench with quick-acting claws.
3.1. Position vehicle on straightening bench, align to the reference holes and firmly bolt using the straightening
set..
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective covers.
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
General warning notes
DANGER
Risk of damage and injury if the safety instructions for body repairs are not observed.
Ignoring the safety instructions for body repairs can result in material damage and injury.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ → 5000IN General information and notes on quality
Straightening set 9PA Cayenne; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Pneumatic body saw PS1; see Gr. 3.5; Workshop Equipment Manual
Oscillating body saw (special electric cutter); see Gr. 3.5; Workshop Equipment Manual
Hot-air gun Leister Elektron; see Gr. 3.5; Workshop Equipment Manual
Cartridge gun VAG 1628; see Gr. 3.5; Workshop Equipment Manual
Spotweld drill; see Gr. 2.4; Workshop Equipment Manual NR.129 00000
Body sealant from Würth Klebt und Dichtet; see Parts Catalogue; Main Group 8
Technical values
Gap dimensions
Note
The figures showing the gap dimensions can be found in the section entitled → Diagram of gap dimensions.
Installation Location:
Note
All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be
completed before the damaged parts are removed.
Preparing
Installation Location:
ATTENTION
Risk of damage if the processing time is not observed!
The binding quality of the adhesive (No. 1) is affected if the processing time is not observed!
1.1. To complete the fit, install the rear spoiler and tail light and set the gap clearance between the rear spoiler
and tail lights according to the adjustment values → gap dimensions.
1.2. Mark the installation position of the bottom part of the side section.
3.1. Fit bottom part of side section according to the markings and fix in
place with tensioning clips.
Subsequent work
7. Apply cavity preservation to the accessible areas of the repair. → 5000IN Cavity preservation.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
2.1. Disengage the wheel housing liner in the transition area between side wall and door seal.
1.2. Screw in fastening screws -4- and tighten to the specified tightening torque → Tightening torque: 3.5 (2.5
ftlb.) Nm +/-0.5 (0.4 ftlb.) Nm
2. Position, align and secure wheel housing liner.
2.2. Screw fastening nuts -3- onto studs and tighten slightly.
2.4. Check that wheel housing liner -1- is positioned correctly in the transition area between side wall and door
seal.
2.5. Tighten all fastening parts -2, 3- to the specified tightening torque. → Tightening torque: 1.5 (1.0 ftlb.)
Nm +/-0.5 (0.4 ftlb.) Nm → Tightening torque: 1.5 (1.0 ftlb.) Nm +/-0.5 (0.4 ftlb.) Nm
Installation Location:
1. Remove front side section trim panel → 702419 Removing and installing front side section trim panel -
chapter on "Removing".
3.1. Unclip rear section of cable for front lid lock -3- at the fastening clips -4- ( -arrows C- ).
4.2. Pull actuating mechanism for front lid -5- up out of the body ( -arrow D- ).
4.3. Unclip rear section of cable for front lid lock -3- at the actuating mechanism for the front lid -5- ( -arrow E- )
and disengage the ball head -7- ( -arrow F- ).
1.1. Engage ball head -7- ( -arrow A- ) and clip in rear section of cable for front lid lock -3- at the actuating
mechanism for the front lid -5- ( -arrow B- ).
1.2. Insert actuating mechanism for front lid -5- into the body ( -arrow C- ).
2.1. Clip in rear section of cable for front lid lock -3- at the fastening clips -4- ( -arrows D- ).
3. Secure insulating mat.
3.1. Swivel insulating mat -1- back ( -arrow E- ) and clip in fastening
clips -2- ( -arrow F- ).
4. Install front side section trim panel → 702419 Removing and installing front side section trim panel - chapter
on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39,
C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Removing front section of cable, emergency release cable, and rear section of
cable
1. Remove front lock lower part → 551719 Removing and installing front lock lower part - chapter on
"Removing".
3. Disengage ball head and remove front section of cable for front lid lock.
3.1. Disengage ball head -2- ( -Arrow C- ) and remove front section of cable for front lid lock -1- ( -Arrow D- ).
The lower part of the lock does not have to be removed from the lock support to facilitate the removal of the front
section of the cable for the front lid lock.
1. Remove front lock lower part → 551719 Removing and installing front lock lower part - chapter on
"Removing".
Installation Location:
1. Remove release for front lid → 551019 Removing and installing release for front lid - chapter on "Removing"
2. Remove front cover (engine compartment) on left → 700219 Removing and installing front cover (engine
compartment) - chapter on "Removing".
3. Remove cowl panel cover → 664419 Removing and installing cowl panel cover - chapter on "Removing".
Installation Location:
Installation Location:
5. Remove rear section of cable for front lid lock.
5.1. Pull rubber sleeves -5- and -6- out of the body ( -arrow E- and
-arrow F- ).
5.2. Pull rear section of cable for front lid lock -7- out of the body ( -arrow G- ).
Removing rear section of cable, emergency release cable, and front section of
cable
Installation Location:
Installation Location:
Installation Location:
1. Install rear section of cable for front lid lock.
1.1. Insert rear section of cable for front lid lock -7- into the body (
-arrow A- ).
1.2. Fit rubber sleeves -5- and -6- to the body ( -arrow B- and -arrow C- ).
2. Connect cable for front lid lock.
2.1. Engage front section of cable for front lid lock -4- ( -arrow D- ) and
close lid -3- at connection piece -1- ( -arrow E- ) until the locking
lugs -2- engage audibly.
3. Fit cowl panel cover → 664419 Removing and installing cowl panel cover - chapter on "Installing".
4. Install front cover (engine compartment) on left → 700219 Removing and installing front cover (engine
compartment) - chapter on "Installing".
5. Install release for front lid → 551019 Removing and installing release for front lid - chapter on "Installing"
Installing emergency release cable
1. Insert emergency release cable and engage ball head.
1.1. Insert emergency release cable -1- ( -Arrow A- ) and engage ball
head -2- ( -Arrow B- ).
2.1. Swivel in emergency release cable -1- and press into place (
-Arrow C- ) until the locking lug ( -arrow- ) engages audibly.
3. Install front lock lower part → 551719 Removing and installing front
lock lower part - chapter on "Installing".
2.1. Swivel in front section of cable for front lid lock -1- and press into
place ( -Arrow C- ) until the locking lug ( -arrow- ) engages audibly.
3. Install front lock lower part → 551719 Removing and installing front
lock lower part - chapter on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
55 17 19 Removing and installing lower part of lock (front) - as of
MY 2003
- Removing lower part of lock at the front
- Installing lower part of lock at the front
Installation Location:
1. Remove front and side covers in engine compartment → 700219
Removing and installing front cover (engine compartment) - chapter
on "Removing".
Installation Location:
Installation Location:
3. Release wiring harness.
3.1. Unclip plug connection -2- at the lock support -1- ( -arrow A- ),
release -arrow B- and remove it -arrows C- .
3.2. Unclip wire harness -3- from the lock support -1- ( -arrows D- ).
3.3. Press temperature sensor -4- out of the lock support -1- ( -arrow E- ).
Installation Location:
5. Disconnecting cable for front lid lock.
5.1. Unclip the connection piece -6- from the body ( -arrow G- ).
5.3. Open the cover -8- at the connection piece -6- ( -arrow I- ) and disengage the front section of the cable for
Installation Location:
6. Release lock support.
6.2. Pull lock support -1- up out of the air guide -11- and press backwards ( -arrows L- ). At the same time,
press the wire harness -3- over the lock support -1- and to the side ( -arrow M- ).
7.1. Pull lock support -1- down ( -arrow N- ), tilt it off ( -arrow O- ) and remove it ( -arrow P- ).
8. Remove emergency release cable and front section of cable for front lid lock → 551419 Removing and
installing cable for front lid lock - chapter on "Removing"
9. Remove contact switch for engine compartment light → 960619 Removing and installing contact switch for
engine compartment light - chapter on "Removing".
10. Remove lower part of lock.
Installation Location:
1. Install lower part of lock.
1.1. Insert lower part of lock -14- into lock support -1- ( -arrow A- ).
Note
The holes in the lower part of the lock -14- and the thread in the lock
support -1- must be aligned in centre position.
1.2. Screw in fastening screws -12- and -13- and tighten to the specified
tightening torque. → Tightening torque: 9 (6.5 ftlb.) Nm +/-1 (0.5
ftlb.) Nm
3. Install emergency release cable and front section of cable for front lid
lock → 551419 Removing and installing cable for front lid lock -
chapter on "Installing"
4. Install lock support.
4.1. Insert lock support -1- ( -arrow B- ) and push emergency release cable -5- and front section of cable for
front lid lock -9- into the lock mount at the same time ( -arrows C- ).
Installation Location:
5. Fasten lock support.
5.1. Push wire harness -3- over the lock support -1- ( -arrow F- ), then
hold lock support -1- and insert it down into the air guide -11- (
-arrows G- ).
Installation Location:
6. Connect cable for front lid lock.
6.1. Engage front section of cable for front lid lock -9- ( -arrow H- ) and close lid -8- at connection piece -6- (
-arrow I- ) until the locking lugs -7- engage audibly.
Installation Location:
Installation Location:
8. Secure wiring harness.
8.1. Press temperature sensor -4- into the lock support -1- (
-arrow M- ).
9.1. Close front lid and check that the upper part of the lock engages
correctly into the lower part of the lock. Adjust the position of the
lock support -1- if necessary by moving it as required.
10. Install front apron → 631519 Removing and installing front apron -
chapter on "Installing" .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
55 18 19 Removing and installing upper part of front lock - as of
MY 2003
- Removing upper part of front lock
- Installing upper part of front lock
Installation Location:
Installation Location:
1. Determine installation position.
1.1. Determine the position of the upper part of the lock with respect to
the lid according to the impression made at the factory -arrow- and
note it down.
2. Detach and remove upper part of front lock.
2.1. Undo fastening nuts -1- and remove upper part of lock -2- .
Installation Location:
1. Mount upper part of front lock.
Installation Location:
2. Position upper part of front lock.
2.1. Adjust the upper part of the lock with respect to the lid according to the noted position -arrow- (factory
impression).
3.1. Tighten fastening nuts -2- to the specified tightening torque → Tightening torque: 12 (9 ftlb.) Nm +/-1.8
(1.5 ftlb.) Nm .
4. Check lid functions.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Adjusting lid
Adjusting lid
Installation Location:
1. Check adjustment. → Test and adjustment value: 3.5 mm +/-0.8 mm → Test and adjustment value: 4
mm +1 mm → Test and adjustment value: 1 mm → Test and adjustment value: 3.5 mm +/-0.8 mm
4.1. Undo fastening screws -4- on both front lid hinges -3- .
5.1. By moving the front lid -1- at the hinges -3- , adjust the contours
according to the wings, main headlights and front spoiler.
5.2. Tighten fastening nuts -2- and fastening screws -4- to specified
tightening torque → Tightening torque: 15 ftlb. +/-2 ftlb. →
Tightening torque : 15 ftlb. +/-2 ftlb. .
6. Fit cowl panel cover → 664419 Removing and installing cowl panel
cover - chapter on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
55 22 19 Removing and installing front lid - as of MY 2003
- Removing front lid
- Installing front lid
Installation Location:
1. Open front lid.
2. Remove insulation for front lid → 700419 Removing and installing insulation for front lid - chapter on
"Removing"
3. Remove wire harness on front lid → 971319 Removing and installing wire harness on front lid - chapter on
"Removing"
4. Remove pneumatic spring on front lid → 553119 Removing and installing pneumatic spring on front lid -
chapter on "Removing"
5.1. Undo fastening nuts -2- and unscrew from the studs -Arrow A- .
5.2. Remove -1- front lid -Arrow B- .
Installing front lid
Installation Location:
1. Install front lid.
1.2. Screw fastening nuts -2- onto studs and position carefully -Arrow B- .
2. Install pneumatic spring on front lid → 553119 Removing and installing pneumatic spring on front lid -
chapter on "Installing"
5. Install wire harness on front lid → 971319 Removing and installing wire harness on front lid - chapter on
"Installing"
6. Install insulation for front lid
→ 700419 Removing and
installing insulation for front lid
- chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove front lid. → 552219 Removing and installing front lid - chapter on "removing"
2. Remove cowl panel cover. → 664419 Removing and installing cowl panel cover - chapter on "removing"
If a front lid hinge fails to work properly, it can be replaced without having to remove the front lid. In such
cases, a second person is required to hold the lid open during the repair process.
Installation Location:
1. Release damping mat
2. Remove hinge.
Installation Location:
1. Fitting hinge
1.2. Roughly align the hinge -4- according to the old impression.
1.3. Insert fastening screws (body side) -3- and tighten to specified tightening torque → Tightening torque: 15
ftlb. +/-2 ftlb. .
2. Fix damping mat
Subsequent work
Subsequent work
1. Install front lid. → 552219 Removing and installing front lid - chapter on "installing"
2. Install cowl panel cover. → 664419 Removing and installing cowl panel cover - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Open front lid.
2. Unfasten the pneumatic spring from the lid and the body.
2.1. A second person should hold the lid to prevent it from accidentally falling.
2.2. Insert a screwdriver -2- between the head of the pneumatic spring and safety clip -3- -A- .
2.3. Release the safety clip -3- by levering the screwdriver -2- towards the pneumatic spring -B- . The safety
clip remains in the head of the pneumatic spring.
3.1. The lid can be fixed in the service position by using special tool
bonnet stay 9704 for further service work → Removing and
installing bonnet stay for service position.
When doing service work, either the standard pneumatic spring can be used or the special tool bonnet stay
9704. → Installing and removing bonnet stay for service position
Installation Location:
1. Position pneumatic spring.
2.1. A second person should hold the lid to prevent it from accidentally falling.
2.2. Position and press the pneumatic spring -1- in the ball heads. The pneumatic spring clicks audibly into
place.
2.3. Check that the safety clips -3- have engaged correctly; repeat procedure, if necessary.
3. Functional inspection.
3.1. Close and open the lid several times to check function and assembly of the gas spring.
3.2. Open front lid fully. The pneumatic spring must hold the lid in its open position.
Note
When installing the bonnet stay, to hold the bonnet in its service position, ensure it is fitted the right way
around. The front lid seal must not make contact with the bonnet stay.
1.1. Mount the bonnet stay -4- with the bend -5- at the bottom.
2.1. The safety clips -6- on both sides of the bonnet stay -4- must be unclipped -A- and opened -B- using a
screwdriver.
2.2. Attach the bonnet stay on both ball heads -C- .
2.3. Close -6- safety clips -D- . The safety clips engage audibly.
3.1. A second person should hold the lid to prevent it from accidentally
falling.
3.2. Unclip the safety clips -6- on both sides -E- and open -F- .
3.3. Remove the bonnet stay from the ball heads -G- .
3.4. Close -6- safety clips -H- . The safety clips engage audibly.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
55 33 19 Removing and installing front lid seal - as of MY 2003
- Removing the front lid seal
- Installing front lid seal
Installation Location:
Note
During removal, the seal must not come into contact with hot engine components or adjacent units. This can
cause damage to the seal.
2.1. Pull the seal from the flanges at the corner pieces -A- , wings -B- , lock carrier -C- and plenum chamber
cover -D- .
2.2. Set the seal down on the engine cover.
Installation Location:
Note
Before replacing, check the existing seal for signs of damage (areas torn, crushed, etc.). If there are signs of
damage, the seal must be replaced.
The seal is pressed onto the flange without any additional sealants.
During installation, the seal must not come into contact with hot engine components or adjacent units. This
can cause damage to the seal.
1.1. Unclip pneumatic spring -1- at the lid end and pivot to the side -E- → 553119 Removing and installing front
pneumatic spring - chapter on "Removing".
1.2. Put on the seal -2- from the top -F- and place on the engine cover.
1.3. Pivot pneumatic spring -1- back again -G- and clip in at the lid end
→ 553119 Removing and installing front pneumatic spring - chapter
on "Installing".
2. Mount front lid seal.
2.1. Pre-position the seal according to the corner pieces -3- and press
onto the sheetmetal flanges -A- in this area.
2.3. Position and press the seal without any tension on the flanges to
the wing -B- , lock mount -C- and plenum chamber cover -D- .
3.1. Pay particular attention to the areas near the tight roundings and corner pieces -3- for correct installation;
there must be no deformation or stretching.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
2. Unscrew fastening screws -2- and withdraw filler flap until fastening clip for securing cord is accessible.
Installation Location:
1. Clip in fixing clip -4- until the locking tabs -arrows A- audibly engage.
5. Tighten fastening screws -2- to specified tightening torque. → Tightening torque: 8 (6 ftlb.) Nm
Note
The figures showing the gap dimensions can be obtained from the chapter → Diagram of gap dimensions.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
3. Loosen both retaining nuts and pull switching element out of the mounting panel.
4. Press and pull off plug from switching element.
3. Insert and position switching element in the mounting panel with both retaining nuts. Make sure that the
locking pin is positioned in the guide.
Information
Emergency operation mechanism
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
1. Carefully lift and pull out strip for switches using a plastic spatula.
1. Insert the switch in the switch panel until it clicks into place.
2. Insert the electrical plug connection for the lid release button and
filler flap until it clicks into place.
3. Position the switch panel in the door panel and press in until it clicks
into place.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
55 57 19 Removing and installing release for rear lid - as of MY
2003
- Preliminary work
- Removing release for rear lid
- Installing release for rear lid
- Subsequent work
Preliminary work
Preliminary work
Remove trim panel for rear lid → 708719 Removing and installing trim panel for rear lid - "Removing section"
Installation Location:
Overview of rear lid release
1. Undo the fastening screws -1 and 2- for the lid release -3- on the
inside of the lid.
2. Release connector -4- on Unscrewing fastening screws for lid
inside of lid at locking tab -5- release
-Arrow A- and pull it off
-Arrow B- .
Loosening release
4. Pull the lid release -3- to the rear out of the assembly opening,
beginning on the right side, and remove -Arrow D- .
Removing release
1. Starting on the left side, insert the lid release -3- into the assembly opening and press upwards -Arrow A-
Installing release
until the lid release -3- engages audibly.
Plugging in connector
3. Screw in and tighten fastening screws -1 and 2- . → Tightening
torque: 3 ftlb. +/-0.4 ftlb.
Installing release
Subsequent work
Subsequent work
Install trim panel for rear lid. → 708719 Removing and installing trim panel for rear lid - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
The lid release switch is located on the door panel on the driver's side in front of the oddments tray.
1. Carefully lift and pull out switch panel using a plastic spatula.
1. Insert the switch in the switch panel until it clicks into place.
2. Insert the electrical plug connection for the lid-release switch and
filler flap until it clicks into place.
3. Position the switch panel in the door panel and press in until it clicks
into place.
Installing switch
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
55 84 19 Removing and installing rear lid release motor - as of MY
2003
- Preliminary work
- Removing rear lid release motor
- Installing rear lid release motor
- Subsequent work
- Information
Preliminary work
Preliminary work
Remove trim panel for rear lid → 708719 Removing and installing trim panel for rear lid - "Removing section"
Installation Location:
Overview of motor for rear lid release
Removing motor
1. Insert motor from the side and use both fastening screws to engage
and position it in the mounting point.
Installing motor
2. Clip control rod into the lid release.
3. Tighten fastening screws.
4. Press the electric plug into the
motor until it clicks into place.
Subsequent work
Subsequent work
Install trim panel for rear lid. → 708719 Removing and installing trim panel for rear lid - "Installing" section
Information
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
55 86 19 Removing and installing lower part of lock at the rear - as
of MY 2003
- Removing lower part of lock at the rear
- Installing lower part of lock at the rear
Installation Location:
1. Open the rear lid.
2. Remove cover for lock carrier. → 703919 Removing and installing cover for lock carrier - chapter on
"Removing"
3.1. Unscrew fastening screws -2- from the lower part of the lock at the rear -1- .
3.2. Remove lower part of lock at the rear -1- .
Installation Location:
1. Install, adjust, and fasten lower part of lock at the rear.
1.1. Position the lower part of the lock at the rear -1- according to the
old impression.
1.2. Screw in fastening screws -2- for the lower part of the lock at the
rear -1- and tighten slightly.
1.3. Carefully close the rear lid and check that the lower part of the lock
at the rear is positioned correctly.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
55 87 19 Removing and installing upper part of rear lock - as of
MY 2003
- Removing upper part of rear lock
- Installing upper part of rear lock
Installation Location:
1. Remove trim panel for rear lid → 708719 Removing and installing trim panel for rear lid - chapter on
"Removing".
3.2. Pull upper part of lock -4- out of the assembly opening -arrow B- until there is access to the electric plug
connection.
3.3. Press in locking tabs of connector -5- -arrows C- and pull off connector.
Installing upper part of rear lock
Installation Location:
1. Install upper part of lock
1.1. Push electric plug connection -5- onto lock upper part -4- -arrow A- .
1.2. Insert upper part of lock into the assembly opening ( -arrow B- ).
1.3. Screw in fastening screws -2, 3- and tighten to the specified tightening torque. → Tightening torque: 25
(19 ftlb.) Nm +/-2.5 (2.0 ftlb.) Nm
3. Check adjustment of rear lid and if necessary adjust lock lower part accordingly → 559015 Adjusting rear lid
- chapter on "Adjusting".
4. Remove trim panel for rear lid → 708719 Removing and installing trim panel for rear lid - chapter on
"Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Technical values
Tightening torques
Tightening torque [Nm]
Location Illustration Thread (ftlb.)
Fastening screw, rear lid hinge -5- M8 25 ± 2.5 (19 ± 2.0)
Rear window fastening nuts on hinge -14- M8 23 ± 2 (17 ± 1.5)
Catch bar mounting point fastening nuts for -18- M6 8 ± 1.2 (6.0 ± 1.0)
the rear window on the rear lid
Fastening screw for guide pin on the body -11- M6 6 ± 0.6 (4.5 ± 0.5)
Fastening screw, adjusting buffer to rear lid -12- M6 6 ± 0.6 (4.5 ± 0.5)
Lock nuts of catch bar on rear lid -20- M6 6 ± 0.6 (4.5 ± 0.5)
Note
The figures showing the gap dimensions can be found in the section entitled → Diagram of gap dimensions.
When adjusting after removing the rear window, begin with the actions under → Adjusting rear screen.
Installation Location:
1. Checking adjustment.
2.1. → 559319 Removing and installing rear pneumatic spring - chapter on "Removing"
3.1. → 708719 Removing and installing rear lid lining - chapter on "Removing"
4.1. → 558619 Removing and installing lower part of rear lock - chapter on "Removing"
7.2. Position spacer pads -2- on both sides on the sealing seam -3- and
attach the screws -4- firmly.
7.3. Note:
Attach the top spacer pads -2- at a distance of 15 cm -dimension a- from the upper sheetmetal overlap (
-arrow- ). Attach the lower spacer pads -2- immediately above the lower sheetmetal overlap ( -arrow- ).
7.4. Loosen the fastening screws -5- of the hinge -6- on the lid -7- .
7.5. Close the lid -7- carefully, until the lid -7- sits on the spacer pads -2- without play.
7.6. By moving the lid -7- on the hinge -6- adjust the outer contours for the side section, for the rear apron, and
for the roof.
7.7. Screw in fastening screws -5- and tighten to the specified tightening torque.
8.1. → 559419 Removing and installing rear lid seal - chapter on "Installing"
9. Installing cover in luggage compartment at the side
9.1. Insert cover -1- ( -arrow B- ) and push back into the side trim panel (
-arrow C- and -arrow C- ).
Installation Location:
Note
The side guide elements of the rear lid must be installed or adjusted so that the side guide pins have a slight
pre-tension to the buffers when the rear lid is closed completely.
1. Checking adjustment.
2.1. Check the adjustment of the guide pin -8- to the guide wedge -9- using the opening gap when the lid is
slightly opened.
Note: the guide pin must contact the guide wedge exactly ( -arrow E- ).
3. Adjusting the side guide pin
3.2. Loosen fastening screw -11- for the guide pin -8- and align the guide
pin with the height of the guide wedge -9- ( -arrow G- ).
4.1. Undo fastening screws -12- for the guide wedge -9- .
4.2. Using a screwdriver, press apart the centre divided guide wedge -9- slightly -arrow I- and completely pull
out the movable integrated stop element -13- ( -arrow K- ).
4.3. Screw down the fastening screws -12- for the guide wedge -9- until the movable stop element -13- of the
rear lid can still barely be moved.
4.4. Close the rear lid with slight pressure over the centre (handle area). The lid may only be closed until it
projects by approx. 2 mm to the outer side section ( -arrows L- ).
Note
This closing process will move the stop elements integrated in the guide wedge into the correct installation position.
5. Fastening the buffer.
5.1. Open the rear lid and tighten the fastening screws -12- for the guide
wedge -9- to the specified tightening torque.
→ 559015 Adjusting rear lid - chapter on "Technical values"
Installation Location:
Note
The adjustment of the rear window must be checked with the rear wing attached, because this is mounted on
the rear window and forms the upper edge for the outer side section and roof.
1. Checking adjustment.
Installation Location:
3. Adjusting the rear screen
3.2. By moving the rear window -16- on the hinge -15- adjust the
contours for the lid and for the outer side section.
Installation Location:
4. Adjusting the catch bar mounting point
4.2. Loosen fastening nuts -18- of the catch bar mounting point -19- .
4.3. By moving the catch bar mounting point -19- in the vertical direction ( -arrow N- ) adjust the contour for the
lid and for the outer side section.
4.4. → 559015 Adjusting rear lid - chapter on "Technical values"
5.2. Adjust the adjustment depth of the rear window by turning the catch bar -21- in the thread -arrow O- .
→ 559015 Adjusting rear lid - chapter on "Technical values"
Note
When closed, the rear window must lie slightly tensioned on the rear
window stops. Adjust the stops if necessary.
6.1.
6.3. Insert a M6 washer -23- with a max. thickness of 1.5 mm and screw
down the rear window stop -22- .
Note
All body gap dimensions and adjustments for the rear lid must be given a final check.
If necessary, fine tuning must be performed for the catch bars of the body or the rear window.
8.1.
9.1. → 708719 Removing and installing rear lid lining - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
Installation Location:
1. Open the rear lid.
Note
Only remove the wiring harness from the rear lid as far as the lid
hinge.
Note
Only remove the wiring harness from the rear lid as far as the lid
hinge.
4. A second person should hold the rear lid -4- to prevent it falling shut.
7. Remove sealant residue from hinge -5- and rear lid -6- .
Installing rear lid
Installation Location:
Note
The flange area between the lid hinge and lid must be sealed with sprayable sealing strip 00000 during
each reinstallation.
1. Apply sprayable sealant in the flange area between the lid hinge -5-
and lid -6- must be coated with sprayable sealant 00000.
2. Mount the rear lid -4- with the help of a second person.
6. Install wire harness on rear lid → 972719 Removing and installing wire harness for tailgate - chapter on
"Installing" [9PAAJ1]→ 972719 Removing and installing wire harness for tailgate - chapter on
"Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]
Subsequent work
Subsequent work
1. Install rear window. → 648619 Removing and installing rear window - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove rear lid → 559019 Removing and installing rear lid - chapter on "Removing".
2. Remove linings for rear lid → 708719 Removing and installing lining for rear lid - chapter on "Removing".
3. Remove rear spoiler → 665819 21 Removing and installing rear spoiler - chapter on "Removing".
4. Remove rear window → 648619 Removing and installing rear window - chapter on "Removing".
5. Remove rear window seal → 649019 Removing and installing rear window seal - chapter on "Removing".
6. Remove trim strip for rear lid → 664719 Removing and installing trim strip for rear lid - chapter on
"Removing".
7. Remove wiring harness on rear lid → 972719 Removing and installing wire harness for tailgate - chapter on
"Removing" [9PAAJ1]→ 972719 Removing and installing wire harness for tailgate - chapter on
"Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]
8. Remove lock upper part → 558719 Removing and installing lock upper part - chapter on "Removing".
9. Remove release for rear lid → 555719 Removing and installing release for rear lid - chapter on "Removing".
10. Remove number plate light → 942919 Removing and installing number plate light - chapter on "Removing".
11. Remove wiper motor for rear window wiper system → 923419 Removing and installing wiper motor for rear
window wiper system - chapter on "Removing".
Installation Location:
1. Removing lateral adjusting buffer.
1.1. Unscrew and remove fastening screws -1, 2- for the lateral
adjusting buffer -3- -Arrow A- .
1.2. Remove the adjusting buffer -3- .
Installation Location:
1. Installing lateral adjusting buffer
1.1. Screw in blind rivet nuts for the lateral adjusting buffer -6- on the
rivet gun, insert on the rear lid and rivet using hand-held blind
rivet nut device NR.125.
1.2. Place lateral adjusting buffer -3- on the rear lid and screw in
fastening screws -1, 2- -Arrows C- .
2. Installing blind rivet nuts for the number plate holder.
2.1. Screw in blind rivet nuts for the number plate holder -7- on the rivet
gun, insert on the rear lid -Arrows D- and rivet using hand-held
blind rivet nut device NR.125.
3. Installing blind rivet nuts for the trim strip holder and the rear window
buffer
3.1. Screw in blind rivet nuts for trim strip holder -8- and rear window
buffer -9- on the rivet gun, insert on the rear lid and rivet using
hand-held blind rivet nut device NR.125.
4.1. Screw in buffer for rear window -4, 5- -arrows E- and tighten to the
specified tightening torque → Tightening torque: 1.0 ftlb. .
Subsequent work
Subsequent work
1. Install rear window release → 646619 Removing and installing rear window release - chapter on "Installing".
2. Install wiper motor for rear window wiper system → 923419 Removing and installing wiper motor for rear
window wiper system - chapter on "Installing".
3. Install number plate light → 942919 Removing and installing number plate light - chapter on "Installing".
4. Install release for rear lid → 555719 Removing and installing release for rear lid - chapter on "Installing"
5. Install rear lock upper part → 558719 Removing and installing rear lock upper part - chapter on "Installing".
6. Install wiring harness on rear lid → 972719 Removing and installing wire harness for tailgate - chapter on
"Installing" [9PAAJ1]→ 972719 Removing and installing wire harness for tailgate - chapter on
"Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]
7. Install trim strip for rear lid → 664719 Removing and installing trim strip for rear lid - chapter on "Installing"
8. Install rear window seal → 649019 Removing and installing rear window seal - chapter on "Installing".
9. Install rear window → 648619 Removing and installing rear window - chapter on "Installing".
11. Remove linings for rear lid → 708719 Removing and installing lining for rear lid - chapter on "Installing".
12. Install rear lid.→ 559019 Removing and installing rear lid - chapter on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
55 91 19 Removing and installing lid hinge - as of MY 2003
- Removing rear lid hinge
- Installing rear lid hinge
Installation Location:
1. Remove rear window → 648619 Removing and installing rear window - chapter on "Removing".
2. Remove rear lid → 559019 Removing and installing rear lid - chapter on "Removing".
3. Remove hinge cover.
3.1. Insert a plastic wedge between the body and hinge cover -1- .
Installation Location:
1. Installing lid hinge
Note
You can check the centre position based on the two top screw holes.
1.4.
1.5. Screw in the two bottom fastening screws -2- and then tighten all
fastening screws -2- to the specified torque → Tightening torque:
19 ftlb. +/-2 ftlb. .
2. Install rear gas spring → 559319 Removing and installing rear gas
spring - chapter on "Installing".
3. Install rear lid → 559019 Removing and installing rear lid - chapter on "Installing".
4. Install rear window → 648619 Removing and installing rear window - chapter on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Note
To allow easier access to the pneumatic spring housing, the roof trim panel must be loosened slightly at the
back once the following parts have been removed.
1. Remove rear roof trim panel. → 708519 Removing and installing rear roof trim panel - section on
"Removing"
2. Remove D-pillar trim panel. → 706919 Removing and installing D-pillar trim panel - section on "Removing"
Installation Location:
ATTENTION
When working on the pneumatic springs of the rear lid, the following safety measures must be observed,
amongst others:
→ To remove the pneumatic springs, they must be in the idle state: rear lid open.
→ The lid must be secured against accidental closing after removing the pneumatic springs.
→ Pneumatic springs must not be opened by force - extreme internal pressure.
Note
A new lid must be used during installation.
7. Loosen safety clips of pneumatic spring for rear lid -4- at ball sockets
using a screwdriver and remove the clips.
8. Pull the pneumatic spring for the rear lid -4- from the ball heads and remove.
Installing pneumatic spring for rear lid
Installation Location:
1. Secure rear lid against accidental closure.
2. Position safety clips of pneumatic spring for rear lid -4- at ball sockets
and snap into place.
3. Press pneumatic spring for rear lid -4- onto the ball heads until the
safety clips are felt to engage.
4.1. Position cover -3- at the front, bend out slightly and insert into the
opening at the back.
4.2. Press cover down all the way round until the butyl seal of the cover
is touching the body evenly.
4.3. Check that the cover makes contact all the way round and is not
bending inwards.
Subsequent work
1. Install rear grab handles left and right. → 683719 Removing and installing rear door grab handle - section on
"Installing"
2. Install D-pillar trim panel. → 706919 Removing and installing D-pillar trim panel - section on "Installing"
3. Install rear roof trim panel. → 708519 Removing and installing rear roof trim panel - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
2. Removing seal.
2.1. Remove the seal from the circumference of the sheetmetal flange -arrows- .
3.1. Remove all the old sealant from the sheetmetal flange.
Installing rear lid seal
Note
A new seal must always be installed.
1.1. Position new seal for rear lid -1- with the connection point -2- in the top centre part of the sheetmetal flange
-3- . The seal air vents must face towards the outside of the vehicle.
2.1. Pay particular attention to the areas near the tight roundings for correct installation; there must be no
deformation or stretching.
2.2. Check the air vents; they must not be closed or covered.
3. Close rear lid.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
1. Open door.
2. Unclip cap.
2.1. Unclip lower cap -1- with a plastic wedge ( -arrow A- ) and remove downwards -arrow B- .
3. Remove lock cylinder.
3.1. Loosen and unscrew fastening screws -2, 3- at the side until the
lock cylinder -4- can be pulled out -arrow C- .
Installation Location:
1. Clip in lock cylinder cover.
1.1. Press cover -5- of lock cylinder -4- on -arrow A- , until locking tabs
-arrows- engage.
2.1. Insert the car key into the lock cylinder and push the lock cylinder in
-4- -arrow B- , turning the car key slightly to the right. Loosen
fastening screws -2 and 3- slightly, if necessary, until the lock
cylinder can be pushed in completely.
2.2. Screw in fastening screws -2, 3- at the sides -arrows C- and
tighten them to the specified tightening torque → Tightening
torque: 3.5 ftlb. +/-0.5 ftlb. → Tightening torque: 0.5 ftlb. .
3.1. Insert cap -1- at the top -arrow D- and clip it into position -arrow E- .
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Technical values
Tightening torques
Installation Location:
1. Open doors.
3.1. Loosen fastening screw -3- -3- at the side and unscrew by approx. 3 mm ( -arrow E- ).
3.3. Loosen fastening screw -2- at the side and unscrew until the housing with lock barrel -4- can be pulled out.
Note
For vehicles with Porsche Entry and Drive
5.1. Pull out door handle -7- slightly ( -arrow G- ) and then pull to the
rear ( -arrow H- ). This disengages the door handle.
6.1. Swivel door handle -7- out by 90° ( -arrow I- ) and carefully pull it
out ( -arrow K- ).
6.2. Remove the rubber washers -8- .
Installation Location:
WARNING
Risk of damage to vehicle doors if door handle is not fitted correctly!
→ An incorrectly fitted door handle can result in problems opening the doors both from inside and outside.
→ Before installing the door handle, make sure that the lock actuation is locked in installation position.
1. Open doors.
2.1. Check that the mounting point -9- was locked correctly in
installation position during removal. If the receiver is not locked, it
can also be secured afterwards.
→ Locking door handle receiver
3.1. Attach securing spring -10- to lock actuation lever using assembly
tool T10118.
→ Locking lock actuation
Note
For vehicles with Porsche Entry and Drive
4.2. Insert door handle -7- , ( -arrow A- ) and swivel it inwards by 90° (
-arrow B- ).
5. Attaching door handle
5.2. Press door handle -7- forward ( -arrow E- ) until you feel it engage.
6.1. Press the lock actuation -6- into the guide on the door handle
-arrow F- .
7.1. Insert vehicle key into the housing with lock barrel and push in the housing -4- ( -arrow G- ) while turning
the vehicle key slightly to the right at the same time. If necessary, loosen fastening screws -2 and 3-
slightly until the housing with lock barrel -4- can be inserted fully.
7.2. Screw in fastening screws -2 and 3- at the side ( -arrow H- ) and tighten to the specified torque. → 571119
Removing and installing door handle - chapter on "Technical values"
8.2. Screw in fastening screw -2- at the side ( -arrow H- ) and tighten to the specified torque. → 571119
Removing and installing door handle - chapter on "Technical values"
Information
Note
To fit the door handle correctly, the receiver -9- must be secured in installation position prior to installation.
The receiver is secured automatically during removal. If the receiver is no longer secured or if new
components are installed, the receiver can also be secured afterwards in accordance with the instructions
below.
1. Pull receiver -9- towards outer door panel and hold in this position ( -arrow C- ).
2. Screw in fastening screw -2- ( -arrow A- ) until the receiver can be pulled into installation position.
4. Unscrew fastening screw -2- ( -arrow B- ) until the mounting point -9- is locked in this position.
Locking lock actuation
1. Light up inside of door with a lamp.
Note
To fit the lock actuation correctly, the securing spring must be hooked into the lock actuation lever before the
door lock is installed.
The secured position of the lock actuation is released automatically when the door handle is first pressed. A
clear clicking sound can be heard when the door handle is first pressed.
2. Guide the assembly tool T10118 -12- between the securing spring
-10- and the lever -11- .
3. The securing spring -10- hooks on to the tool with a rotary
movement.
4. Pull the securing spring -10- towards the outside of the door
-arrow L- until the spring engages audibly in the locking lug of the
lever -13- .
5. Unhook the tool and remove it.
Note
Pull carefully on the lock actuation to check that it is secured in
installation position. Repeat the steps listed above if necessary.
Removing and installing wiring harness for Porsche Entry and Drive system
1.1. Unclip the wiring harness -1- from the basic door frame at the
marked positions ( -arrows- ).
2.1. Pull out the wiring harness -1- from the door handle base plate -2- . While doing this, press the rubber
sleeve -3- together.
Note
A malfunction occurs only after the vehicle is locked for the first time.
In other words: if a door handle was fitted incorrectly, the affected
door can be opened and closed without difficulty until the vehicle is
locked for the first time. After that, the door cannot be opened either
from inside or outside. Given this, it is important to perform a function
test before the door is closed.
2. With the door open, use a screwdriver to engage the bolt in the door
lock fully in the second notch.
Note
If the bolt in the door lock does not open, press the door button to make sure that the individual door opening
function is deactivated. If the door lock still does not open, the door lock was assembled incorrectly.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove front door sub-frame. → 573019 Removing and installing front door sub-frame - chapter on
"Removing".
Installation Location:
2.1. Pull door lock -3- with bowden cable -4- out of the door sub-frame -arrow D- . When doing so, push the
grommet -5- out of the door sub-frame.
2.3. Unclip fastening of bowden cable -6- on door lock -3- -arrow F- .
Installing door lock
Installation Location:
Installation Location:
1. Installing door lock
1.1. Engage bowden cable -4- on door lock actuating mechanism and
swivel by 90° -arrow A- .
1.2. Clip in fastening of bowden cable -6- on door lock -3- ( -arrow B- ).
1.3. Fit lock retaining bracket -7- -arrow C- .
1.4. Insert blind rivet -8- and rivet lock retaining bracket -7- to the door
lock -3- from the rear -arrow D- .
2.2. Pass bowden cable -4- through door sub-frame, insert door lock -3-
-arrow E- and fit the grommet -5- .
3.1. Insert the blind rivets -2- and rivet lock retaining bracket to door sub-frame -arrows F- .
3.2. Insert electric plug connections -arrows G, H- until they click audibly into place.
3.3. Position the cover -1- and clip it into place -arrow I- .
Subsequent work
Subsequent work
1. Install front door sub-frame. → 573019 Removing and installing front door sub-frame - chapter on
"Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
Note
The counterplate -3- of the striker pin -1- is permanently fixed to the B-pillar structure. After the striker pin has
been removed, the counterplate remains in the lower end position on the B-pillar.
1. Open door.
Installation Location:
1. Installing, adjusting and fastening the striker pin
1.2. Screw in fastening screws -2- for the striker pin -1- and tighten
slightly.
1.3. Carefully close door and check that the striker pin is positioned
correctly with respect to the lock.
2. Remove markings.
2.1.
3. Close door.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove door handle → Removing door handle.
2. Remove front door trim → Removing and installing front door trim.
Technical values
Tightening torques
Installation Location:
Note
Close the door window in order to improve accessibility to the door wiring harness when removing the front
door unit carrier.
1. Removing rear assembly opening covers, loosening lock mounting and KESSY wiring harness - For all
vehicles:
1.1. Unclip the top and bottom assembly opening covers -1- and -2- .
1.2. Unscrew fastening screws
-3- on door lock.
2.2. Press out rubber sleeve -C- and slide cable outwards through the opening.
3.1. Unclip the top and bottom assembly opening covers -4- and -5- .
3.2. Pull off rubber sleeve -7- between the door and A-pillar.
5.1. Raise the door sub-frame -12- evenly at the front and rear until the
guide pins -13- and -16- are fully released from the holding slots
-14- and -15- .
5.2. Remove the door sub-frame from the basic door frame -17- .
1.1. Move the three adjustable fastening elements ( -Arrow A, B, C- ) on the door sub-frame to their home
position. Screw the screw element -19- fully into the basic element -18- .
Note
The screw elements have left-handed threads.
3.1. Mount the door sub-frame -12- on the basic door frame -17- .
3.2. Insert guide pins -13- and -16- into the holding slots -14- and -15- .
4. Fixing door sub-frame to basic door frame, linking up electrical plug connection and tightening lock
4.1. Fix the door sub-frame to the basic door frame by screwing in the fastening screws -9, 11- . Press the door
sub-frame upwards and screw in fastening screws slightly.
4.2. Push wiring harness -10- from inside through the door sub-frame and the door opening and press rubber
sleeve on the wiring harness -10- from inside into the door opening.
4.4. Press on the rubber sleeve -7- between the doors and A-pillar.
4.5. Screw in new fastening screws -3- on the door lock and tighten to the specified tightening torque →
Tightening torques.
5.1. The fastening screw -11- secures the front bearing position (holding slot -15- for guide pin -16- ). This
bearing point cannot then be adjusted!
5.2. Close the door carefully.
Note
The setting is achieved by bracing
the door unit carrier with the basic
door frame using the adjustable
fastening elements. If the required
joint measurements cannot be
achieved, it may be necessary to
unscrew the fastening screws -
9,11- and reset the adjustable
fastening elements to the basic
position.
5.3. The window frame (door sub-frame) must be adjusted with respect
to the roof frame and B-pillar ( -arrow D- ). The pivoting points in
this case are the holding slots -14- , -15- and the guide pins -13- ,
-16- . Adjust the gap dimensions on the door sub-frame.
5.5. Tighten fastening screws -9, 11- to the specified tightening torque. → Tightening torques
Installation Location:
7. Clipping in covers of front assembly openings
7.1. Clip in the top and bottom assembly opening covers -4- and -5- .
9.1. Pull KESSY wiring harness in through the opening. Install rubber sleeve in the unit carrier until it engages
completely ( -Arrow A- ).
9.2. Insert plug into the socket ( -Arrow B- ) until it clicks into place.
Subsequent work
Subsequent work
1. Install rear-view mirror → Removing and installing rear-view mirror.
2. Install front door trim → Removing and installing front door trim.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Affixing foam seal to the rear of the support plate
1.1. Clean marked area -1- on the support plate -2- . The area must be
completely free of any greasy residues.
1.2. Stick self-adhesive foam seal in the marked area -1- . The foam
seal must not be deformed or stretched in the process.
2. Securing the support plate on the door frame
2.1. Place the support plate -2- on the door frame -3- and align it
roughly.
2.2. Fix the support plate to the door frame using four rivets -4- . Rivet the rivets in the sequence -A, B, C, D- .
Hand riveting tool for pop rivets NR.124-1 Nozzle tips for hand rivet extractors NR.124-2
Installation Location:
3. Installing front cover cap
Installation Location:
4. Installing rear cover cap
4.1. Engage rear cover -7- on door sub-frame with locking tab and
swivel to end position ( -arrows- ).
4.2. Rivet the rear cover -7- to the door sub-frame -8- .
Installation Location:
5. Inserting expanding nuts
Installation Location:
6. Installing inner window shaft moulding
6.1. Position the inner window shaft moulding -10- in the front area (
-Arrow A- ).
6.2. Centre the inner window shaft moulding -10- and press it evenly onto the door sub-frame over the entire
length ( -Arrow B- ).
7.1. Lay out window seal -11- as shown and fit to the window frame in
the top corner.
7.2. Insert the plastic cover -12- ( -Arrow C- ) and push it against the
corner area of the window seal ( -Arrow D- ).
7.3. Attach the window seal to the door frame along the B-pillar, roof
rail, and A-pillar.
Note
As a general rule, a new door seal must be fitted when assembling the door unit carrier.
9.1. Fit door seal -13- to the door sub-frame in the front area.
9.2. The connection point -14- of the door seal must be in the marked
area ( -Arrow E- ).
9.3. Lay door seal -13- all round the door sub-frame and fit it. Take care
not to deform or stretch the seal, especially in rounded areas.
9.4. Check that door seal -13- is seated properly on door sub-frame.
Installation Location:
10.1. Push the grommet -15- into the door frame until it clicks into place.
11. Installing wiring harness
11.2. Clip wiring harness -16- into the door sub-frame at the marked
positions ( -Arrows A to F- ).
Installation Location:
12. Completing the door lock
12.1. Engage bowden cable -18- on door lock actuating mechanism and
swivel by 90° ( -Arrow I- ).
12.2. Clip in bowden cable mount -19- on door lock -17- ( -Arrow J- ).
Installation Location:
14. Installing door lock
14.2. Guide bowden cable -18- through the door sub-frame and insert
door lock -17- ( -Arrow A- ).
15. Riveting the door lock
15.2. Insert the rivets -25- ( -Arrows D- ) and rivet the door lock to the
door sub-frame.
15.3. Position the cover -40- and clip it into place ( -Arrow F- ).
16.1. Place the power window mechanism on the door frame as shown. Make sure the cables are in the correct
position ( -Arrow E- ).
16.3. Fix the guide rails -27- with 2 rivets each -28- and rivet to the door frame.
16.4. Clip retaining clip -29- in the door sub-frame and engage the cable.
Installation Location:
17. Stick on damping material -33- .
18. Install door glass. → 644019 Removing and installing front door
window - section on "Installing"
19.1. Connect window power motor -34- and control unit -35- and clip into place.
19.2. Position the power window drive on the power window gear.
19.3. Screw in fastening screws
-36- and tighten to the
specified tightening torque.
→ Tightening torque: 3.0
(2.0 ftlb.) Nm +/-0.3 (0.2
ftlb.) Nm
21.1. Position the loudspeaker -38- and rivet to the door sub-frame at the
marked positions ( -arrows- ).
5. Remove cover.
Removing cover
Installing cover for front window guide
1. Position cover.
1.1. Push in cover into the corner of the door sub-frame below the window guides.
2. Engage cover.
2.1. Press in the cover into the corner of the door sub-frame until the cover is felt to engage.
2.2. Check that sealing lip is fitted correctly.
Pushing in cover under window guide Positioning cover
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Engaging cover
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Installation Location:
1. Pulling plug off door lock
2.1. Pull door lock -2- with inner door lock release -3- out of the door sub-frame ( -Arrow C- ). When doing so,
push the grommet -4- out of the door sub-frame.
3. Removing inner door lock release
3.1. Unclip fastening of inner door lock release -5- on door lock -2-
-Arrow D- ).
3.2. Swivel inner door lock release -3- by 90° and disengage on door
lock actuating mechanism ( -Arrow E- ).
3.3. Remove inner door lock release -3- .
Installation Location:
1. Installing inner door lock release
1.1. Engage inner door lock release -3- on door lock actuating
mechanism and swivel by 90° ( -Arrow A- ).
1.2. Clip in fastening of inner door lock release -5- on door lock -2- (
-Arrow B- ).
Installation Location:
3.1. Insert the pop rivets -1- and rivet lock retaining bracket to door sub-
frame ( -Arrows D- ).
3.2. Insert plug until the locking tabs engage audibly ( -Arrows E, F- ).
Subsequent work
Subsequent work
1. Install front door sub-frame. → 573019 Removing and installing front door sub-frame - section on "Installing"
Installation Location:
1. Remove door trim panel cover → 706119 Removing and installing door trim panel cover - chapter on
"Removing".
Installation Location:
1. Insert door handle.
1.1. Insert door handle -1- into the door trim panel ( -Arrow A- ).
1.2. Push door handle -1- in fully and press into position ( -Arrow B- ).
3. Install door trim panel cover → 706119 Removing and installing door trim panel cover - chapter on
"Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Technical values
Note
The figures showing the gap dimensions can be found in the section entitled → Diagram of gap dimensions.
Installation Location:
WARNING
Expansion screws are used to fasten the hinge mountings.
→ To correctly adjust the front door in the B-pillar area, the hinge screw connections on the door must be
loosened.
→ The fastening screws of the hinge mounting are expansion screws and must always be replaced after
loosening.
→ For this reason, these screws must only be tightened by hand (max. 10 Nm (7.5 ftlb.)) until the doors are
adjusted correctly.
1.1. Unscrew fastening screws -1- , -2- and -3- and replace them. The new screws must initially be tightened by
hand only (max. 10 Nm (7.5 ftlb.)).
1.2. By moving the door-side hinge halves on the door -4- , -5- vertically and horizontally, adjust the contour
with respect to the wing and the rear door → Diagram - body gap dimension.
1.3. Tighten fastening screws -1- , -2- and -3- to the specified tightening torque → Tightening torque: 20 (15
ftlb.) Nm +/-3 (2.0 ftlb.) Nm → Torque angle: 90 ° .
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
2. Removing door
2.1. Pull off rubber sleeve -1- between door and A-pillar -Arrow A- .
3.1. Lift the door up slightly -arrows- until the hinge bolts are extended
out of the hinge halves on the door side.
Installation Location:
WARNING
Expansion screws are used to fasten the hinge mountings.
→ For this reason, the fastening screw of the lower hinge mounting must always be replaced when installing
the door.
Note
Before inserting the door, the upper and lower hinge joint must be lubricated.
1.1. Engage the door into the hinge bolts from above -arrows- .
2. Installing door
2.1. Screw in fastening nut of upper hinge mounting -3- and tighten
using the appropriate special tool → Tools and materials →
Tightening torque: 30 (22 ftlb.) Nm +/-3 (2 ftlb.) Nm .
2.2. Screw in fastening screw of lower hinge mounting -4- and tighten
using the appropriate special tool → Initial tightening: 20 (15 ftlb.)
Nm +/-15 % → Final tightening: 90 ° .
2.4. Press on rubber sleeve -1- between door and A-pillar -Arrow B- .
Subsequent work
Subsequent work
1. Teach power windows → 90 Work instructions after disconnecting the battery.
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove front door → 575119 Removing and installing front door - chapter on "Removing".
2. Remove front door trim → 705919 Removing and installing front door trim - chapter on "Removing".
3. Remove rear-view mirror → 668919 Removing and installing rear-view mirror - chapter on "Removing".
4. Remove cover for front door → 662219 Removing and installing cover for front door - chapter on
"Removing".
5. Remove front window bay seal → 644819 Removing and installing front window bay seal - chapter on
"Removing".
6. Remove door handle → 571119 Removing and installing door handle - chapter on "Removing".
7. Remove front door sub-frame. → 573019 Removing and installing front door sub-frame - chapter on
"Removing"
8. Remove outer rubber seal for front door → 576519 Removing and installing outer rubber seal for front door -
chapter on "Removing".
1.1. Unscrew fastening screw for securing door handle base plate -1-
and remove it ( -arrow A- ).
Installation Location:
Installation Location:
2. Removing the rubber pads and rubber sleeve
2.1. Lever the rubber pads -4- out towards the rear using a plastic
wedge ( -arrow D- ).
2.2. Remove the rubber sleeve -5- by pulling it towards the rear ( -arrow E- ).
Assembling front door
Installation Location:
1.1. Insert rubber sleeve -5- into the existing opening -Arrow F- .
1.2. Insert rubber buffer -4- into the existing opening -Arrow G- . When doing this, make sure the retainining
lips are fitted correctly.
2.1. Insert the door handle base plate -3- from the rear ( -Arrow H- ). When doing this, make sure the fastening
clips -2- click into place correctly.
2.2. Screw in fastening screw for door handle base plate -1- -Arrow I- and tighten to specified torque →
Tightening torque: 4.5 (3.5 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm .
Subsequent work
Subsequent work
1. Install outer rubber seal for front door → 576519 Removing and installing outer rubber seal for front door -
chapter on "Installing".
2. Install front door → 575119 Removing and installing front door - chapter on "Installing".
3. Install front door sub-frame. → 573019 Removing and installing front door sub-frame - chapter on "Installing"
4. Install door handle → 571119 Removing and installing door handle - chapter on "Installing".
5. Install front window bay seal → 644819 Removing and installing front window bayseal - chapter on
"Installing".
6. Install cover for front door → 662219 Removing and installing cover for front door - chapter on "Installing".
7. Install rear-view mirror → 668919 Removing and installing rear-view mirror chapter on "Installing".
8. Install front door trim → 705919 Removing and installing front door trim - chapter on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove front door → 575119 Removing and installing front door - chapter on "Removing".
2. Remove front side-section trim panel→ 702419 Removing and installing front side-section trim panel -
chapter on "Removing".
3. Remove dashboard bracket → 701219 Removing and installing dashboard bracket - chapter on "Removing".
Note
To remove and adjust the upper door hinges, the instrument panel and the carrier for the instrument panel
must be removed.
Note
The rear fastening screw is fitted from inside the vehicle.
2.1.
2.2. Unscrew the fastening screws -1, 2- for the upper door hinge -3-
using the special tool and remove. M8 multiple-tooth socket
wrench insert NR.29
3.1.
3.2. Unscrew the fastening screws -4, 5- for the lower door hinge -6-
using the special tool and remove. M8 multiple-tooth socket
wrench insert NR.29
4.1. Unscrew the fastening screw -9- for the lower door hinge -6- using
the special tool and remove. M8 multiple-tooth socket wrench
insert NR.29
5.1. Unscrew the fastening screw -7- for the upper door hinge -3- using
the special tool and remove. M8 multiple-tooth socket wrench
insert NR.29
5.2. Remove upper door hinge -3- .
WARNING
Expansion screws are used to fasten the door hinges.
→ The fastening screws of the upper and lower door hinges are expansion screws and must always be
replaced after loosening.
→ For this reason, these screws must only be tightened by hand until the doors are adjusted correctly.
1.1. Position upper door hinge -3- on the door and secure by screwing
in the fastening screw -7- .
The fastening screw must provisionally be tightened by hand only.
→ Tightening torque: <10 (7.5) Nm
3.1. Insert front door using the pre-mounted hinges -Arrows E- and carefully close it completely.
Note:
When closing the door, make sure that the electrical plug connections are not crushed or damaged. If
necessary, insert plug and press in grommet.
4. Secure the upper door hinge.
4.1. Secure the upper door hinge -3- by screwing in the fastening screw
-2- from inside the vehicle -Arrow F- .
The fastening screw must provisionally be tightened by hand only.
→ Tightening torque: <10 (7.5 ftlb.) Nm
5.1. Secure the lower door hinge -6- by screwing in the fastening screw
-5- from inside the vehicle -Arrow G- .
The fastening screw must provisionally be tightened by hand only.
→ Tightening torque: <10 (7.5 ftlb.) Nm
6. Set the upper door hinge and tighten from the inside of the vehicle.
6.1. Position front door correctly using the upper door hinge -3- .
6.2. Screw in the fastening screw -2- from the inside of the vehicle and
to the specified tightening torque using the special tool, and then
tighten to the torque angle. M8 multiple-tooth socket wrench
insert NR.29
→ Tightening torque: 20 (15 ftlb.) Nm +/-3 (2.0 ftlb.) Nm →
Tightening torque: +90 °
7. Set the lower door hinge and tighten from the inside of the vehicle
7.1. Position front door correctly using the lower door hinge -6- .
7.2. Screw in the fastening screw -5- from the inside of the vehicle and
to the specified tightening torque using the special tool, and then
tighten to the torque angle. M8 Multiple-tooth socket wrench
insert NR.29
→ Tightening torque: 20 (15 ftlb.) Nm +/-3 (2.0 ftlb.) Nm →
Tightening torque: +90 °
8.1. The front doors must be removed again to allow access to the
fastening screws -1- and -4- from the outside of the vehicle.
9. Tighten the upper door hinge from the outside of the vehicle.
9.1. Screw in the fastening screw -1- from the outside of the vehicle
-Arrow H- and to the specified tightening torque using the special
tool, and then tighten to the torque angle. M8 multiple-tooth
socket wrench insert NR.29
→ Tightening torque: 20 (15 ftlb.) Nm +/-3 (2.0 ftlb.) Nm →
Tightening torque: +90 °
10. Tighten the lower door hinge from the outside of the vehicle.
10.1. Screw in the fastening screw -4- from the outside of the vehicle -Arrow I- and to the specified tightening
torque using the special tool, and then tighten to the torque angle. M8 Multiple-tooth socket wrench
insert NR.29
→ Tightening torque: 20 (15 ftlb.) Nm +/-3 (2.0 ftlb.) Nm → Tightening torque: +90 °
Subsequent work
Subsequent work
1. Install front door → 575119 Removing and installing front door - chapter on "Installing".
3. Install dashboard bracket → 701219 Removing and installing dashboard bracket - chapter on "Installing".
4. Install front side-section trim panel→ 702419 Removing and installing front side-section trim panel - chapter
on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
57 63 19 Removing and installing rubber seal for front door - as of
MY 2003
- Removing the rubber seal for front door
- Installing the rubber seal for front door
Installation Location:
1. Open front door.
2. Remove A-pillar trim. → 705719 Removing and installing A-pillar trim - chapter on "Removing"
3. Remove front grab handles. → 683519 Removing and installing grab handle - chapter on "Removing"
4. Remove front side section trim. → 702419 Removing and installing front side section trim - chapter on
"Removing"
5. Removing seal.
Note
The roof cover must be carefully pulled down slightly in the upper area. Make sure that the roof cover does not
buckle.
5.1. Remove seal -1- all round sheetmetal flange -arrows- .
Installation Location:
Note
The roof cover must be carefully pulled down slightly in the upper area.
Make sure that the roof cover does not buckle.
1.1. Position new seal for front door -1- with connection point -2- in the
area indicated (on A-pillar structure) -Arrow A- of the sheetmetal
flange -3- . The seal air vents must face towards the outside of the
vehicle.
2.1. Pay particular attention to the areas near the tight roundings for correct installation; there must be no
deformation or stretching.
2.2. Check the air vents; they must not be closed or covered.
3. Install front side section trim. → 702419 Removing and installing front side section trim - chapter on
"Installing"
4. Install front grab handles. → 683519 Removing and installing grab handle - chapter on "Installing"
5. Install A-pillar trim. → 705719 Removing and installing A-pillar trim - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
57 65 19 Removing and installing outer rubber seal for front door -
as of MY 2003
- Removing the outer rubber seal for front door
- Installing the outer rubber seal for front door
Installation Location:
1. Remove front door → 575119 Removing and installing front door - chapter on "Removing".
3.1. Pull out seal end piece at top -5- behind door sub-frame -6-
-Arrow B- .
3.2. Remove rubber seal -2- , starting at top of door flange -3-
-Arrow C- .
1.1. Insert rubber seal -2- into seal of door panel -4- -Arrow A- and fit it
to the door flange -3- , starting at the bottom -Arrow B- .
1.2. Insert seal end piece at top -5- behind the door sub-frame -6-
-Arrow C- .
Installation Location:
2. Clip in cover of front assembly opening.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
Only the central locking switches on the rear switch panels can be removed and installed.
1. Lever out the entire power window switch using a plastic spatula.
3. Use two screwdrivers to press the switch panel housing apart and pull out the switch.
Note
Only the central locking
switches on the rear switch
panels can be removed and
installed.
Removing switch
1. Insert the switch in the switch panel until it clicks into place.
Installing switch
2. Insert the electrical plug connection in the power window switch until
it clicks into place.
4. Make sure that the power window switch is positioned evenly on the gap.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39,
C45, C46, C98, C99
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove right side trim panel for rear luggage compartment.→ 700319 Removing and installing side trim
panel for rear luggage compartment - chapter on "Removing"
WARNING
Risk of damage and injury!
If care is not taken, electrical and electronic components may br destroyed.
Installation Location:
Overview of control unit for rear convenience system
1. Undo the two fastening screws -Arrows A- and pull out control unit
to the side.
1. Press electric connectors into control unit until they are felt to
engage.
Note
If the control unit is replaced, it must be coded using the Porsche System Tester. This is to adapt the control
unit to the vehicle and equipment.
If possible, before the control module is removed and replaced, a read-out of the vehicle data should be
obtained using the Porsche System Tester.
During coding, 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.
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 texts 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. >>
Continue.
3. Using the →| key, move from the vehicle type to the control modules.
4. Select Rear/doors with the cursor keys and press the >> key.
5. Select Control unit replacement with the cursor keys and press the >> key.
6. Select Read out values (codings) and press the >> key.
7. The message Coding read-out complete will appear on the screen of the Porsche System Tester >> .
8. Switch off ignition and replace control unit. → 578919 Removing and installing control unit for rear
convenience systems (rear control unit) - "Removing" section.
9. Switch on ignition. After replacement of the control module, the vehicle data that has been read out is
transferred to the new unit using the "Write data" menu option (see Section 6). Press the >> key.
10. System Tester displays Coding write-in complete. Press the >> key.
11. Quit menu, switch off ignition, lock then unlock vehicle and read out fault memory once more.
Subsequent work
Subsequent work
1. Install right side trim panel for rear luggage compartment.→ 700319 Removing and installing side trim panel
for rear luggage compartment - chapter on "Installing"
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
1.1. Clean marked area -1- on the support plate -2- . The area must be
completely free of any greasy residues.
1.2. Stick self-adhesive foam seal in the marked area -1- . The foam
seal must not be deformed or stretched in the process.
2. Secure the support plate on the door frame.
2.1. Place the support plate -2- on the door frame -3- and align it roughly.
2.2. Fix the support plate to the door frame using four rivets -4- . Rivet
the rivets in the order -A, B, C, D- .
Installation Location:
1. Install front cover cap.
1.1. Attach front cover -6- to the door sub-frame using the locking tab and swivel to end position ( -arrows- ).
Installation Location:
2. Install rear cover cap.
2.1. Attach rear cap -7- to the door sub-frame using the locking tab and swivel to end position ( -arrows- ).
Installation Location:
3. Insert expanding nuts.
3.1. Press in the expanding nuts -9- on the lower edge of the door unit carrier.
1.2. Place the plastic covers -11- and -12- ( -arrow C- and -arrow D- )
and push them against the corner area of the window seal (
-arrow E- and -arrow F- ).
Installation Location:
2. Install triangular cover.
2.1. Insert triangular cover -13- into the window seal -10- and clip it in -arrow G- .
3. Install inner window shaft moulding.
3.1. Position the inner window shaft moulding -14- in the front area ( -arrow H- ).
3.2. Centre the inner window shaft moulding -14- and press it evenly on
to the door unit carrier over the entire length ( -arrow I- ).
4. Turn the component on the assembly table.
Note
When assembling the door unit carrier, as a general rule a new door seal must be fitted.
1. Fit door seal -15- to the door unit carrier in the front area.
2. The connection point -16- of the door seal must be in the marked area ( -arrow J- ).
3. Lay door seal -15- all round the door unit carrier and fit it. Take care no deformation or stretching occurs,
especially in the area near roundings.
4. Check that door seal -15- is seated properly on door unit carrier.
5.1. Push the grommet -16- into the door frame until it clicks into place.
2. Clip wiring harness -17- into the door unit carrier at the marked positions ( -arrows A, D- ).
3. Guide front area (transition to
B-pillar) of wiring harness
through the door unit carrier (
-arrow E- ) and pull it out to
the front ( -arrow F- ). Make
sure that the rubber grommet
is not twisted when fitted
1.1. Engage bowden cable -19- on door lock actuating mechanism and
swivel by 90° ( -arrow G- ).
1.4. Rivet the lock retaining bracket -21- to the door lock -18- from the rear ( -22- ). Hand riveting tool for pop
rivets NR.124-1
Nozzle tips for hand rivet extractors NR.124-2
2. Clip in towing element.
3.2. Guide bowden cable -19- through the door unit carrier and insert
door lock -18- ( -arrow A- ).
4. Rivet the door lock.
4.1. Insert electrical plug connections ( -arrow B, C- ) until they click audibly into place.
4.2. Insert the rivets -25- ( -arrows D- ) and rivet the door lock to the door unit carrier.
4.3. Position the cover -40- and clip it into place ( -arrow F- ).
1.1. Place the power window mechanism on the door frame as shown. Make sure the cable is in the correct
position ( -arrow E- ).
1.2. Clip in power window gear -26- in the door sub-frame.
1.3. Fix the guide rails -27- with 2 rivets each -28- and rivet to the door
frame.
1.4. Apply lubricant (grease) to the guide rails and move the sliding pads -29- manually.
2. Insert door side window.→ 646019 Removing and installing rear door window - chapter on "installing"
3. Installing the power window drive
3.1. Connect power window motor -32- and control unit -33- and clip
into place.
3.2. Position the power window drive on the power window gear.
1. Install holder.
1.1. Install holder for inside door handle -36- , insert fastening screws -37- and tighten with specified tightening
torque.
→ Tightening torque: 4.5 ftlb. +/-0.5 ftlb.
2. Install rear door unit carrier. → 583019 Removing and installing rear door unit carrier - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove rear door. → 585119 Removing and installing rear door - section on "Removing"
2. Remove rear door trim. → 707319 Removing and installing rear door trim - section on "Removing"
3. Remove rear door cover. → 664219 Removing and installing rear door cover - section on "Removing"
4. Remove rear window channel seal. → 646819 Removing and installing rear window channel seal - section
on "Removing"
5. Remove door handle. → 581119 Removing and installing door handle - section on "Removing"
6. Remove rear door sub-frame. → 583019 Removing and installing rear door sub-frame - section on
"Removing"
7. Remove outer rubber seal for rear door. → 586319 Removing and installing rubber seal for rear door -
section on "Removing"
1.1. Unscrew fastening screw for securing door handle base plate -1- and remove it ( -arrow A- ).
Installation Location:
2. Remove rubber grommet.
2.1. Remove the rubber sleeve -4- by pulling it towards the rear (
-arrow D- ).
1.1. Insert the rubber sleeve -4- into the existing opening ( -arrow E- ).
When doing this, make sure the holding lips are fitted correctly.
2.1. Insert the door handle base plate -3- from the rear ( -arrow F- ). When doing this, make sure the fastening
clips -2- click into place correctly.
2.2. Screw in fastening screws for the door handle base plate -1- -arrow G- and tighten to tightening torque. →
Tightening torques: 4.5 (3.5 ftlb) Nm +/-0.4 (0.5 ftlb.) Nm
Subsequent work
Subsequent work
1. Install outer rubber seal for rear door. → 586319 Removing and installing rubber seal for rear door - section
on "Installing"
2. Install rear door. → 585119 Removing and installing rear door - section on "Installing"
3. Install rear door sub-frame. → 583019 Removing and installing rear door sub-frame - section on "Installing"
4. Install door handle. → 581119 Removing and installing door handle - section on "Installing"
5. Install rear window channel seal. → 646819 Removing and installing rear window channel seal - section on
"Installing"
6. Install rear door cover. → 664219 Removing and installing rear door cover - section on "Installing"
7. Install rear door trim. → 707319 Removing and installing rear door trim - section on "Installing"
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Open door.
3. Remove housing.
3.2. Loosen and unscrew the fastening screw -2- at the side -arrow B- until the housing -3- can be pulled out.
5.1. Remove door unit carrier → Removing rear door unit carrier.
5.2. Remove Porsche Entry and Drive wiring harness→ Removing and
installing wiring harness for Porsche Entry and Drive system.
Installation Location:
1. Open door.
WARNING
Risk of damage to vehicle doors if door handle is not fitted correctly!
→ An incorrectly fitted door handle can result in problems opening the doors both from inside and outside.
→ Before installing the door handle, make sure that the lock actuation is locked in installation position.
2.1. Check that the mounting point -9- was locked correctly in installation position during removal. If the receiver
Installing door handle
is not locked, it can also be fixed in place subsequently → Locking door handle receiver.
3.1. Attach securing spring -10- to the lock actuation lever using the
assembly tool T10118 → Latching the lock actuation.
4. Install Porsche Entry and Drive wiring harness. For vehicles with
Porsche Entry and Drive only
4.1. Install Porsche Entry and Drive wiring harness → Removing and
installing wiring harness for Porsche Entry and Drive system.
4.2. Install door unit carrier → Removing and installing rear door unit
carrier.
6.1. Press door handle -6- inwards -arrow C- and hook it in behind the receiver -9- -arrow D- .
6.2. Press door handle -6- forward -arrow E- until it locks with an audible click.
7. Attach lock actuation
7.1. Press the lock actuator -5- into the guide on the door handle
-arrow F- .
8. Install housing.
8.1. Install housing -3- -arrow G- . If necessary, slacken fastening screw -2- until the housing can be inserted
completely.
8.2. Screw in fastening screw -2- at the side -arrow H- and tighten to the specified tightening torque. →
Tightening torque: 4.5 (3.5 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
Note
To fit the door handle correctly, the receiver -9- must be secured in installation position prior to installation.
The receiver is secured automatically during removal. If the receiver is no longer secured or if new
components are installed, the receiver can also be secured afterwards in accordance with the instructions
below.
1. Pull receiver -9- towards outer door panel and hold in this position ( -Arrow C- ).
2. Screw in fastening screw -2- ( -Arrow A- ) until the receiver can be pulled into installation position.
4. Unscrew fastening screw -2- ( -arrow B- ) until the mounting point -9- is locked in this position.
Note
To fit the lock actuation correctly, the securing spring -10- must be hooked into the lock actuation lever -11-
before the door handle is installed.
The secured position of the lock actuation is released automatically when the door handle is first pressed. A
clear clicking sound can be heard when the door handle is first pressed.
1. Light up inside of door with a lamp.
2. Guide the assembly tool T10118 -12- between the securing spring
-10- and the lever -11- .
4. Pull the securing spring -10- toward the outer side of the door
-arrow L- until the spring can be felt to engage in the locking lug of
the lever -13- .
5. Unhook the tool and remove it.
Note
Pull carefully on the lock actuation to check that it is secured in
installation position. Repeat the steps listed above if necessary.
Removing and installing wiring harness for Porsche Entry and Drive system
1.1. Unclip the wiring harness -1- from the basic door frame at the marked positions -arrows- .
2.1. Pull out the wiring harness -1- from the door handle base plate -2- . While doing this, press the rubber
sleeve -3- together.
3. Install wiring harness
3.1. Install in reverse order.
Note
A malfunction occurs only after the vehicle is locked for the first time. In other words: if a door handle was
fitted incorrectly, the affected door can be opened and closed without difficulty until the vehicle is locked for
the first time. After that, the door cannot be opened from inside or outside. Given this, it is important to
perform a function test before the door is closed.
2. With the door open, use a screwdriver to engage the bolt in the door lock fully in the second notch.
Note
If the bolt in the door lock does not open, press the door button in the driver's door to make sure that the
individual door opening function is deactivated. If the door lock still does not open, the door lock was
assembled incorrectly.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Remove rear door sub-frame → 583019 Removing and installing rear
door sub-frame - chapter on "Removing".
2. Pull plug off door lock.
3.1. Pull door lock -3- with bowden cable -4- out of the door sub-frame -arrow D- . When doing so, push the
grommet -5- out of the door sub-frame.
3.2. Drill out the pop rivet -8- from the rear and pull lock retaining
bracket -7- out of the door lock -3- ( -arrow E- ).
3.3. Unclip fastening of bowden cable -6- on door lock -3- ( -arrow F- ).
3.4. Swivel bowden cable -4- by 90° and disengage on door lock actuating mechanism ( -arrow G- ).
Installation Location:
1.1. Engage bowden cable -4- on door lock actuating mechanism and swivel by 90° ( -arrow A- ).
1.2. Clip in fastening of bowden cable -6- on door lock -3- ( -arrow B- ).
1.4. Insert pop rivet -8- and rivet lock retaining bracket -7- to the door lock -3- from the rear -arrow D- ). Hand
riveting tool for pop rivets NR.124-1
2.2. Pass bowden cable -4- through door sub-frame, insert door lock -3- ( -Arrow E- ) and fit the grommet -5- .
3.1. Insert blind rivets -2- and rivet lock retaining bracket to door sub-frame -Arrows F- Hand riveting tool for
blind rivets NR.124-1.
3.2. Insert electrical plug connections 1 -Arrows G, H- until they click
audibly into place.
3.3. Position the cover -1- and clip it into place -Arrow I- .
4. Install rear door sub-frame → 583019 Removing and installing rear door sub-frame - chapter on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
1. Open door.
2. Determine striker pin position.
2.1. Mark the position on the C-pillar using a felt-tipped pen. Use the
impression of the striker pin -arrows- .
Note
The counterplate -3- of the striker pin -2- is permanently fixed to the
C-pillar structure. After the striker pin has been removed, the
counterplate remains in the lower end position on the C-pillar.
3.1.
Installation Location:
1. Installing, adjusting and fastening the striker pin
1.2. Screw in fastening screws -1- for the striker pin -2- and tighten
slightly.
1.3. Carefully close door and check that the striker pin is positioned
correctly with respect to the lock.
2. Remove markings.
2.1. Remove the felt-tipped pen markings from the paint surface of the C-pillar using a suitable cleaning agent.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Removing door handle
Installation Location:
Note
When removing the rear door unit carrier, make sure that the door window is closed.
1. Remove rear assembly opening covers, detach lock mounting and KESSY wiring harness.
2.2. Pull off the rubber sleeve -7- between the doors and B-pillar.
3.1. Unscrew fastening screws for door sub-frame -8, 9- and -11- .
3.2. Press the rubber sleeve -10- inwards and push the plug connection back through the door aperture.
4. Remove door unit carrier.
4.1. Raise the door sub-frame
-12- evenly at the front and
rear until the guide pins -13-
and -16- are fully released
from the holding slots -14-
and -15- .
Installing rear door sub-frame
Installation Location:
1. Move adjustable fastening elements to their home position.
Note
The screw elements have left-handed threads.
3.1. Push the plug connection inward through the door aperture and press in the rubber sleeve -10- from inside
into the door aperture.
3.2. Mount the door sub-frame -12- on the basic door frame -17- .
3.3. Insert guide pins -13- and -16- into the holding slots -14- and -15- .
4. Fix door unit carrier to basic door frame, link up electrical plug connection and tighten lock.
4.1. Fix the door sub-frame to the basic door frame by screwing in the fastening screws -9- and -11- . The
fastening screws should only make light contact.
4.4. Screw in new fastening screws -3- on the door lock and tighten to the specified tightening torque. →
Tightening torque: 20 (15 ftlb.) Nm -2 (1.5 ftlb.) Nm
5. Adjust door unit carrier.
5.1. The fastening screw -11- secures the front bearing position (holding slot -15- for guide pin -16- ). This
bearing point cannot then be adjusted!
5.2. Close the door carefully. Installing rear door sub-frame
Note
The figures showing the gap
dimensions can be found in
the section entitled →
Diagram of gap dimensions.
5.3. The window frame (door sub-frame) must be adjusted with respect
to the roof frame and B-pillar ( -arrow D- ). The pivoting points in
this case are the holding slots -14- , -15- and the guide pins -13-
and -16- . Adjust the gap dimensions on the door sub-frame. →
Test and adjustment value: 5 mm
5.4. Tighten fastening screws -9, 11- to the specified tightening torque. → Tightening torque: 33 (24 ftlb.) Nm
+/-3 (2 ftlb.) Nm
7.1. Clip in the top and bottom assembly opening covers -4- and -5- .
8. Clip in rear assembly opening covers and connecting KESSY wiring harness.
8.1. For all vehicles:
clip in the top and bottom
assembly opening covers
-1- and -2- .
Subsequent work
Subsequent work
1. Install rear door trim.
1.1. → 707319 Removing and installing rear door trim - section on "Installing"
3.1. → 90 Work instructions after disconnecting the battery
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
58 37 19 Removing and installing inner door lock release - as of
MY 2003
- Removing inner door lock release
- Installing inner door lock release
Installation Location:
Installation Location:
2. Pull plug off door lock.
4.1. Unclip fastening of inner door lock release -5- on door lock -2-
-Arrow D- ).
4.2. Swivel inner door lock release -3- by 90° and disengage on door
lock actuating mechanism ( -Arrow F- ).
Installation Location:
1. Install inner door lock release.
1.1. Engage inner door lock release -3- on door lock actuating
mechanism and swivel by 90° ( -Arrow A- ).
Installation Location:
2. Install door lock.
2.2. Guide inner door lock release -3- through door sub-frame, insert door lock -2- ( -Arrow C- ) and fit the
grommet -4- .
3. Rivet the door lock.
3.1. Insert the blind rivets -1- and rivet lock retaining bracket to door
sub-frame -Arrow D- .
3.2. Insert plug until the locking tabs engage audibly ( -Arrows E, F- ).
4.1. → 583019 Removing and installing rear door sub-frame - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove cover for door trim panel. → 706119 Removing and installing door trim panel cover - chapter on
"removing"
Installation Location:
1. Remove door handle.
Installation Location:
1. Insert door handle.
1.1. Insert door handle -1- into the door trim panel -Arrow A- .
1.2. Push door handle -1- in fully and press into position -Arrow B- .
Subsequent work
Subsequent work
1. Install sun blind on door window.Only vehicles with sun blind on door window. → 689619 Removing and
installing sun blind on door window - chapter on "installing"
2. Install cover for door trim panel. → 706119 Removing and installing door trim panel cover - chapter on
"installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Remove ignition key.
2. Removing door.
2.1. Pull off rubber sleeve -1- between door and B-pillar -Arrow A- .
2.3. Unscrew fastening nut of upper hinge joint -3- using the appropriate special tool→ Tools and materials.
2.4. Unscrew fastening screw on lower hinge mounting -4- located on door side using the appropriate special
tool→ Tools and materials.
3.1. Lift the door -arrows- lightly upwards until the hinge bolts are extended out of the hinge halves on the door
side.
Note
Before inserting the door, the upper and lower hinge joint must be lubricated.
1. Insert door.
1.1. Engage the door -arrows- in the hinge bolts from above .
WARNING
Expansion screws are used to fasten the hinge mountings.
→ For this reason, the fastening
screw of the lower hinge
mounting must always be
replaced when installing the
door.
2. Install door.
2.1. Screw in fastening nut of upper hinge mounting -3- and tighten
using the appropriate special tool → Tools and materials →
Tightening torque: 30 (22 ftlb.) Nm +/-3 (2 ftlb.) Nm .
2.2. Screw in fastening screw of lower hinge mounting -4- and tighten
using the appropriate special tool → Tools and materials → Initial
tightening: 20 (15 ftlb.) Nm +/-3 (2 ftlb.) Nm → Final tightening:
+90 ° .
2.4. Press on the rubber sleeve -1- between the door and A-pillar ( -arrow B- ).
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1. Removing rear door
Technical values
Installation Location:
1. Remove upper door hinge
1.1. Unscrew fastening screws -1- for the upper door hinge -2- using the
relevant special tool and remove them.
→ Tools and materials
1.2. Remove upper door hinge -2- .
2.1. Note: The rear fastening screw -4- is fitted from inside the vehicle.
2.2. Unscrew fastening screws -3, 4- for the lower door hinge -5- using the relevant special tool and remove
them.
→ Tools and materials
3.1. Unscrew fastening screw -8- for the lower door hinge -5- using the
relevant special tool and remove it.
→ Tools and materials
3.2. Remove lower door hinge -5- .
4.1. Unscrew fastening screw -6- for the upper door hinge -2- using the
relevant special tool and remove it.
→ Tools and materials
Installation Location:
WARNING
Expansion screws are used to fasten the door hinges.
→ The fastening screws of the upper and lower door hinges are expansion screws and must always be
replaced after loosening.
→ For this reason, these screws must only be tightened by hand (max. 10 Nm (7.5 ftlb.)) until the doors are
adjusted correctly.
1.1. Position upper door hinge -2- on the door and secure by screwing
in the fastening screw -6- .
Temporarily tighten the fastening screw hand-tight only (max. 10
Nm (7.5 ftlb.)).
2. Fit lower door hinge on door
2.1. Position lower door hinge -5- on the door and secure to the door by screwing in the fastening screws -7, 8-
.
Temporarily tighten the fastening screws hand-tight only (max. 10 Nm (7.5 ftlb.)).
3.1. Insert rear door using the pre-mounted hinges -Arrows A- and
close fully.
4. Secure the upper door hinge
4.1. Secure the upper door hinge -2- by screwing in the fastening
screws -1- ( -Arrow B- ).
Temporarily tighten the fastening screws hand-tight only (max. 10
Nm (7.5 ftlb.)).
5.1. Secure the lower door hinge -5- by screwing in the fastening
screws -3, 4- ( -Arrows C, D- ).
Temporarily tighten the fastening screws hand-tight only (max. 10
Nm (7.5 ftlb.)).
6. Make electric plug connection
6.2. Press on the rubber sleeve -10- between the door and A-pillar (
-Arrow E- ).
7.1. Position rear door correctly using the upper door hinge -2- .
7.2. Tighten fastening screws -1- to the specified tightening torque using
the appropriate special tool.
→ Tightening torques
→ Tools and materials
8.1. Position rear door correctly using the lower door hinge -5- .
8.2. Tighten fastening screws -3, 4- to the specified tightening torque using the appropriate special tool.
→ Tightening torques
→ Tools and materials
Subsequent work
Subsequent work
1. Adjust rear door
1.1. → Adjusting rear door
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove B-pillar trim panel.
3.1. → 700319 Removing and installing rear luggage compartment side-panel lining - "Removing" chapter
Installation Location:
1. Remove seal.
Installation Location:
1. Install new seal:
1.1. Position new seal for rear door 1 with join -2- in the area indicated
(on B-pillar structure) -Arrow A- of the sheetmetal flange -3- . The
seal air vents must face towards the outside of the vehicle.
1.2. Press down new seal all around the sheetmetal flange.
2. Check whether the installation is correct.
2.1. Pay particular attention to the areas near the tight roundings for
correct installation; there must be no deformation or stretching.
2.2. Check the air vents; they must not be closed or covered.
Subsequent work
Subsequent work
1. Install inner door sill trim.
2.1. → 700319 Removing and installing rear luggage compartment side-panel lining - "Installing" chapter
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
Installation Location:
2. Remove cover of front assembly opening
3.1. Pull out retaining lug at top of rubber seal -2- from fixing device on
door inner panel -3- ( -Arrow B- ).
3.2. Remove rubber seal -4- , starting at top of door flange -5- (
-Arrows C- ).
Installation Location:
2. Remove rear rubber seal
2.1. Pull out top of rubber seal -6- from C-pillar panel -7- ( -Arrow D- ).
2.2. Release clip fastenings of rubber seal -6- , starting at the top using a plastic wedge -12- ( -Arrows E- ).
2.3. Remove rubber seal -6- , starting from the top at the flange of the wheel opening -8- ( -Arrows F- ).
Installation Location:
Installation Location:
1. Install front rubber seal
1.1. Insert rubber seal -4- into the seal of the door panel -9- (
-arrow A- ) and fit it to the door flange -5- , starting at the bottom (
-arrow B- ).
1.2. Insert the seal end piece at the top -10- behind the door unit carrier
-11- ( -arrow C- ).
1.3. Press retaining lug at top of rubber seal -2- into the fixing device on the inner door panel -3- ( -arrow D- ).
2. Clipping in cover of front assembly opening
Installation Location:
Installation Location:
1. Install rear rubber seal
1.1. Push rubber seal -6- - starting at the middle -arrow F- - onto flange of wheel opening -8- ( -arrow G- ).
1.3. Insert top end piece -12- of rubber seal -6- behind the C-pillar panel -7- ( -arrow I- ).
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
DANGER
Danger of cut injuries when removing and installing car windows!
Always wear protective gloves when working on car windows.
Wear protective goggles when cutting out car windows.
Only replace the cutting knife with the power supply disconnected so that the cutter is not switched
on accidentally.
→ Cutting out glued car windows may lead to cut injuries to the skin and eyes due to flying glass splinters and
may result in cut injuries from the knife of the cutter.
ATTENTION
Danger of paint damage and damage to the label with the vehicle identification number if windscreen is
removed incorrectly!
When cutting out the windscreen, ensure that the label with the vehicle identification number is not
damaged!
ATTENTION
Danger of injury due to unintentional activation of airbag units!
The ground strap of the battery must be disconnected during work on the airbag system and
alignment bench jobs when the body is being repaired!
After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar
tools must not be started until after a waiting period of 1 minute!
ATTENTION
Danger of damage to the seats during the removal and fitting of the sliding roof frame!
Fold the rear seat assembly forward and tip the front seat backrest backwards during the removal
and fitting of the sliding roof frame.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Model year
Colour designation Colour code
01 02 03 04 05 06 07 08 09 10
Sand white R9A X X X
Black 041 X X X
Sea blue A5G X X X
Model year
Colour designation Colour code
01 02 03 04 05 06 07 08 09 10
Titanium metallic D7Z X X X
Lapis blue metallic M5W X X X
Basalt black metallic C9Z X X X
Carmona red metallic M3W X X X
Jarama beige metallic M1W X X X
Lagoon green metallic M6W X X X
Prosecco metallic M1X X X X
Crystal silver metallic A7W X X X
Dark olive metallic M6X X
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
60 Overview of exterior colours - as of MY 2003
- Information
Information
Model year
Colour designation Colour code
01 02 03 04 05 06 07 08 09 10
Sand white R9A X X X X
Black 041 X X X X
Sea blue A5G X X X X
Model year
Colour designation Colour code
01 02 03 04 05 06 07 08 09 10
Titanium metallic D7Z X X X X
Lapis blue metallic M5W X X X X
Basalt black metallic C9Z X X X X
Carmona red metallic M3W X X X X
Jarama beige metallic M1W X X X X
Lagoon green metallic M6W X X X X
Prosecco metallic M1X X X X X
Crystal silver metallic A7W X X X X
Dark olive metallic M6X X X
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
A- Double cartridge gun VAS 5237 - see Workshop Equipment Manual, Chapter 3.5
B- Suction cups VAG 1344 - see Workshop Equipment Manual, Chapter 3.5
C- Special electric cutter (fine) VAG 1561 A - see Workshop Equipment Manual, Chapter 3.5
D- Flashing knife, U-type 639.031.130.22; see Parts Catalogue, Main Group 8
H- 2-component window adhesive, contains set components H1-H8; see Parts Catalogue, Main Group 8
H1 - Cleaning solution
H2 - Primer
H3 - Activator
H4 - Swab
H5 - Cartridge, component A
H6 - Cartridge, component B
H7 - Mixing nozzle
H8 - Processing nozzle
Note
The table below shows how to use cleaners, primers and activators when preparing the bonding surface.
ATTENTION
Note
In addition to this manual, observe the relevant job descriptions for body repairs!
1.1. Pierce the membrane in the nozzle connection of components A and B (aluminium cartridge) -H5- with a
screwdriver and extend the opening. Remove flanged cover on end of cartridge.
4.1. By activating the valve -arrow- allow the pressure piston to move out
slowly until both components of the bonding material emerge at the
mixing pipe.
4.2. Wipe off the emerging adhesive.
5.1. Screw processing nozzle -H8- onto the mixing nozzle -H7- .
Note
In this position, the closed surfaces must be visible at the horizontal mixing nozzle from above and below and
the mixing blade of the mixer insert from the sides.
6.2.
7.1. By activating the valve -arrow- allow the pressure piston to move out
slowly until the adhesive is visible in the processing pipe.
Note
In order to ensure that the substance is completely mixed, apply a 30
mm long adhesive bead of fresh adhesive to a piece of cardboard
before processing.
If the contents of the cartridge is not completely used up, the processing nozzle should not be removed until
the adhesive has hardened on the cartridge. A new processing nozzle must be used for subsequent bonding
work.
8.1.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Information
If the roof cannot be closed using the rotary switch (e.g. roof jammed), the roof can be closed using the
emergency operation mechanism. This deactivates anti-crushing protection and the roof is closed with full engine
torque.
Note
Before closing the roof assembly using the emergency operation mechanism, make sure that the end
positions of the roof cannot be blocked by foreign bodies.
WARNING
Danger of injury! Anti-crushing protection is deactivated in emergency operation mode.
2. Keep pressing the emergency operation mechanism -arrow- until the roof is completely closed.
WARNING
Danger of injury! Risk of material damage!
→ Do not reach into the moving area of the mechanism when opening and closing the roof assembly.
→ Anti-crushing protection is deactivated in emergency operation mode.
→ If there is danger, release the rotary switch immediately or activate it in the opposite direction, or switch off
the ignition.
→ After replacing a motor or moving the lids with the ignition switched off, first close the roof and initialise the
limit position.
→ Never open the roof assembly without having initialised the limit position of the motors. Danger of collision
for the two rear roof segments!
Note
Activate the switch for at least 5 seconds, but do not activate for more than 40 seconds.
When the maximum duration of operation (> 40 seconds) is exceeded, the fault code 0409 (Rotary switch
emergency button signal is permanently displayed) can be stored in the control unit.
The fault code can only be detected if the fault memory of the control unit is read out using the Porsche
System Tester.
To initialise the end stops, the lids of the roof assembly are first closed and then opened briefly and closed
again. The sun blind is only closed.
If the lids are already closed before initialising the end stops, these are opened briefly and then closed again
for initialisation purposes. If the sun blind is already closed, it is not moved during this procedure.
Initialisation must be completed fully as otherwise the roof cannot be operated electrically.
1. Switch on ignition and turn rotary switch to the position "Close roof fully". Wait until the roof remains in any
position.
2. Hold the rotary switch in this position -arrow- . The closing operation starts after approx. 5 seconds. Keep
the rotary switch pressed until the sun blind and the roof are closed. First the sun blind is closed; then the lid
of the roof assembly is closed, opened briefly, and closed again. The rear lid of the roof assembly only
closes after the rotary switch is released -arrow- .
3. Relieve the seals from strain by briefly opening and then closing the roof again.
4. Read out the fault memory with the Porsche System Tester and
erase existing faults.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Disconnect battery. → Work instructions after disconnecting battery
2. Remove roof joint cover strip. → 663619 Removing and installing roof joint cover strip - section on
"Removing"
Installation Location:
Note
3 persons are necessary to be able to take off the roof assembly after
removal.
Preparing roof assembly for panoramic roof and vehicle for installation
Preparing roof assembly for panoramic roof and vehicle for installation
1. Check the sealing joint -9- and impact cover -10- for damage or detachment on the roof assembly, if
necessary, replace seal and cover. → 604019 Removing and installing panel of panoramic roof - chapter on
"Replacing"
Note
The sealing strap must be
replaced before re-installing
the roof assembly.
4. Clean flange of body in contact area of the roof assembly with cleaning agents.
5. Affix sealing strap -7- on rear positioning bolt -6- all the way around starting on the fitting flange of the roof
assembly.
5.1. Cut off the sealing strap -7- in the area of the gap so that it forms a 45° joint -arrow- .
5.2. Affix the sealing strap -7- in the area of the corners -A- so that it is free of tension.
WARNING
Danger of injury when reaching into the mechanism while opening and closing the Panorama roof
system.
→ Do not reach into the moving area of the mechanism when opening and closing the Panorama roof system.
→ If there is danger, release the rotary switch immediately or activate it in the opposite direction, or switch off
the ignition.
ATTENTION
Danger of material damage due to closing/opening the roof system with a limit position that is not
initialised.
→ After replacing a motor or moving the roof segments with the ignition switched off, first close the roof and
initialise the limit position.
→ Never open the panoramic roof without having initialised the limit position of the motor! Danger of collision
for the two rear roof segments!
3 persons are necessary to be able to position the roof assembly when installing on vehicle.
The roof assembly will be aligned automatically using the positioning bolts attached to the roof assembly
when installing.
Installation Location:
1. Prepare roof assembly and vehicle for installation. → 600619 Removing and installing roof assembly
(panoramic roof) - section on "Preparing"
2. Place roof assembly -1- on roof frame and insert the positioning bolts -6- in the roof frame.
3. Screw in fastening nuts -5- and tighten in the sequence shown -a to c- and -d to h- to the specified
tightening torque. → Tightening torque: 10 (7.5 ftlb.) Nm +/-0.5 (0.3 ftlb.) Nm
4. Connect electric plug connection of vehicle wiring harness -4- to control unit for roof assembly until it is felt to
engage.
Reworking
1. Install roof joint cover strip. → 663619 Removing and installing roof joint cover strip - section on "Installing"
3. Close the roof assembly with the emergency operation mechanism and initialise final deactivation. →
Closing roof assembly (panorama roof) with emergency operation mechanism and initialising final
deactivation
5. Check roof assembly functions by completely opening and closing or raising it.
6. Read out the fault memory for the roof assembly and if a fault was recorded in the fault memory, carry out a
diagnosis using the PIWIS tester 9718.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
WARNING
Danger of injury! Risk of material damage!
→ Do not reach into the moving area of the mechanism when opening and closing the roof assembly.
→ Anti-crushing protection is deactivated in emergency operation mode.
→ If there is danger, release the rotary switch immediately or activate it in the opposite direction, or switch off
the ignition.
→ Never open the roof assembly without having initialised the limit position of the motors. Danger of collision
for the two rear roof segments!
Note
When the maximum duration of operation (> 40 seconds) is exceeded, the fault code 0409 (Rotary switch
emergency button signal is permanently displayed) can be stored in the control unit.
Initialisation must be completed fully as otherwise the roof cannot be operated electrically.
1. Switch on ignition and turn rotary switch to the position "Close roof fully". Wait until the roof remains in any
position.
2. Hold the rotary switch in this position -arrow- . The closing operation starts after approx. 5 seconds. Keep
the rotary switch pressed until the sun blind and the roof are closed. First the sun blind is closed; then the lid
of the roof assembly is closed, opened briefly, and closed again. The rear lid of the roof assembly closes
only after the rotary switch is released -arrow- .
3. Relieve the seals from strain by briefly opening and then closing the roof again.
4. Read out the fault memory with the Porsche System Tester and remedy any faults.
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The number of plug connections can vary, depending on the vehicle
equipment. Disconnect all plug connections for removing the roof
console.
4. Press the electric connector -1- on the printed circuit board -a- and unplug.
5. Press the electric connector -2- on the control unit for the garage door opener -a- and unplug.
7. Press electric connector -4- on the passenger compartment sensor -a- and unplug.
8. Disconnect the electric connector -5- .
10. Pull off the foam from the plug connection and carefully separate the tie-wrap.
11. Disconnect the plug connection.
12. Disconnect the electrical plug connection on the sliding roof switch.
13. Carefully disconnect the retaining stop -A- and pull out the switch
from above -B- .
1. Join the plug connection, fold the wires, and secure them with a tie-
wrap.
2. Pull the foam over the plug connection.
3. Position the switch in the roof console and carefully press it down.
Make sure that the retaining stops engage on the switch.
Note
Observe the line routing, danger of pinching!
Bending clips up and outwards on
perimeter of roof console
5. Carefully bend the six clips around the perimeter of the roof console up and slightly outwards
-in direction of arrow- to increase the preload of the clips.
6. Engage the roof console on the roof liner and plug in all electrical
plug connections -1, 2, 3, 4, 5- until the plugs audibly click into place.
7. Fold up roof console, clip it in the roof liner and screw down using the
four fastening screws. Close the glasses compartment and clip in the
light unit cover.
8. Switch on ignition and check the proper function of the sliding roof
switch.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Removing headliner. → 708419 Removing and installing headliner - "Removing" section
Because of its size, the roof requires two motors to open and close it.
When removing the left motor cut open the tie-wrap -a- ; when removing the right motor cut open the tie-wrap
-b- .
Installation Location:
Cutting tie-wraps
1 - Panel 1
2 - Panel 2
3 - Panel 3
4 - Motor for adjusting panels 1 and 2 1. Release the connector
5 - Motor for adjusting panel 3 -Arrow A- and pull it off
-Arrow B- .
Removing motor
Note
Before installing motor, check the drive shafts for wear and abrasion.
Note
After installation of the motor, the limit stops for the roof assembly must be re-initialised in the control unit.
1. Insert motor -Arrow A- and engage drive pinion -c- by turning back
and forth -Arrows B- in the helical drive -d- .
Subsequent work
1. Install headliner. → 708419 Removing and installing headliner - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
60 14 23 Removing and installing motor for sliding roof - as of MY
2003
- Removing motor for sliding roof
- Installing motor for sliding roof
Installation Location:
Remove the ignition key and switch off the radio.
Note
The number of plug connections can vary, depending on the vehicle equipment. Disconnect all plug
connections for removing the roof console.
4. Press the electric connector on the printed circuit board and unplug.
5. Detach the roof console from the mounts on the roof liner at the left and right.
Installation Location:
1. Press in the electric plug until it clicks into place.
2. Position motor and secure with the fastening screws. Tightening torque 2.5 ftlb.
3. Attach the roof console to the mounts on the roof liner at the left and right and plug in all electrical
connections.
4. Push the electrical plug for the circuit board until it clicks into place.
5. Fold up roof console, clip it in the roof liner and screw down using the two fastening screws. Close glasses
compartment.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
ATTENTION
Danger of damage to the seats during the removal and fitting of the sunroof frame!
Fold the rear seat assembly forward and tip the front seat backrest backwards during the removal
and fitting of the sunroof frame.
Installation Location:
1. Pull off water drain hoses at the front -2- .
Installation Location:
Installation Location:
4. Unscrew the front fastening screws.
Installation Location:
1.1. Insert the sliding roof frame -1- with an assistant through the rear lid
opening into the passenger compartment.
Note
The punches have a diameter of 10 mm or 12 mm.
1.2. Position frame for sliding door -1- on the roof frame and attach to the locating bores with punches -6 and 7-
.
Installation Location:
2. Tighten the fastening screws -4- in the sequence shown -4a, 4b- and -4c to 4e- . → Tightening torque: 8 (6
ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
3. Push electric plug connection -5- onto sunroof drive until locking tabs audibly engage.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Open sliding roof.
Installation Location:
2. Remove air deflector.
3. Remove spring.
Installation Location:
1. Install spring.
Installation Location:
2. Install air deflector.
2.2. Press air deflector -1- into the cut-out of the sliding roof frame -2- ( -Arrow C- ).
2.3. Clip in the air deflector -1- ( -Arrow D- ).
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1 - Panel 1
2 - Panel 2
3 - Panel 3
4 - Panel 4
5 - Air deflector
1. Fully open panels 1 and 2 of panoramic roof
2. Unclip cover -16- ( -Arrow A- ) and pull out to the rear ( -Arrow B- ).
3. Unscrew fastening screws -7- and lay air deflector aside -5- .
Installation Location:
1 - Panel 1
2 - Panel 2
3 - Panel 3
4 - Panel 4
5 - Air deflector
1. Fully open panel 3 of panoramic roof.
Installation Location:
1 - Panel 1
2 - Panel 2
1. Move panel 3 of panoramic roof to ventilation position.
3 - Panel 3
4 - Panel 4 2. Move panel 2 of panoramic roof to tilting position.
5 - Air deflector
3. Undo fastening screws -6- .
4. Press air deflector -7- to the front ( -Arrow A- ) and remove together
with panel -3- of panoramic roof.
1. Swing air deflector -7- together with the spring -8- outwards in a
downward direction.
3. Twist spring -8- ( -Arrow A- ) and remove from bolt of air deflector
-7- .
Installing panel of panorama roof
1. Push and twist spring -8- onto bolt of air deflector -7- ( -Arrow A- ).
Installation Location:
1 - Panel 1
2 - Panel 2 1. Insert panel -3- of panoramic roof and engage air
3 - Panel 3 deflector -7- on the fixed panel -4- .
4 - Panel 4
5 - Air deflector
Installation Location:
1 - Panel 1
2 - Panel 2
3 - Panel 3
4 - Panel 4
5 - Air deflector
1. Insert panel -2- of panoramic roof.
Installation Location:
1 - Panel 1
2 - Panel 2
3 - Panel 3
4 - Panel 4
5 - Air deflector
1. Push plastic washer -14- onto guide pin of stop -13- .
3. Press guide -12- gently outwards ( -Arrow A- ) and engage stop -13-
together with guide pin in the guide -12- ( -Arrow B- ).
4. Counter front bearing -11- , screw in fastening screw -10- and tighten
so that panel 1 of panoramic roof can still be moved easily.
5. Position end stop -9- , counter, screw in fastening screw -8- and
tighten so that panel 1 of panoramic roof can still be moved easily.
6. Position air deflector -5- , screw in fastening screws -7- and tighten to
the specified tightening torque. → Tightening torque: 2 ftlb. +/-0.5
ftlb.
7. Fully close panels 1 and 2 of panoramic roof and check adjustment
of panel 1, correcting if necessary. → 604019 Removing and
installing panel for panoramic roof - chapter on "adjusting"
8. Insert cover guide -16- into mounting -15- and slide it in ( -Arrow A- ).
Installation Location:
1 - Panel 1
2 - Panel 2
3 - Panel 3 1. Adjust height -Y- and gap -Z- on panorama roof
4 - Panel 4 panel -3- at the rear. → Adjustment value: 1 mm
5 - Air deflector +/-0.5 mm → Adjustment value: approx. 7.1 mm
4. Adjust height -X- and gap -Z- on panorama roof panel -3- at the front.
→ Adjustment value: 1 mm +/-0.5 mm → Adjustment value:
approx. 7.1 mm
Installation Location:
1 - Panel 1
2 - Panel 2
3 - Panel 3
4 - Panel 4
5 - Air deflector
1. Adjust height -Y- and gap -Z- on panorama roof panel -2- at the rear.
→ Adjustment value: 1 mm +/-0.5 mm → Adjustment value:
approx. 7.1 mm
4. Adjust height -X- and gap -Z- on panorama roof panel -2- at the front. → Adjustment value: 1 mm +/-0.5
mm → Adjustment value: approx. 7.1 mm
Installation Location:
1 - Panel 1
2 - Panel 2
3 - Panel 3
4 - Panel 4
5 - Air deflector
1. Adjust height -X- on panorama roof panel -1- at the front. → Adjustment value: 0.5 mm +/-0.5 mm
2. Tighten fastening screws -10- to the specified tightening torque. → Tightening torque: 4 (3 ftlb.) Nm +/-0.5
(0.5 ftlb.) Nm
3. Adjust height -Y- and gap -Z- on panorama roof panel -1- at the rear. → Adjustment value: 1 mm +/-0.5
mm → Adjustment value: approx. 7.1 mm
4. Tighten fastening screw -8A- to the specified tightening torque. → Tightening torque: 4 (3 ftlb.) Nm +/-0.5
(0.5 ftlb.) Nm
5. If necessary, loosen fastening screw -8B- as well, adjust height -Y- and tighten fastening screw -8B- to the
specified tightening torque. → Tightening torque: 4 (3 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
4. Turn over the adhesive film -10- and place it on the sealing bead -11- from above.
5. Press down evenly on the adhesive film -10- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
60 40 19 Removing and installing sunroof panel - as of MY 2003
- Removing sunroof panel
- Installing sunroof panel
- Adjusting sunroof panel
Installation Location:
1. Lift sunroof panel.
3.1. Unclip bellows -2- at the top and bottom in the front area towards
the centre of the vehicle.
4. Unhook bellows.
4.1. Unhook bellows -2- at the top in the rear area backwards out of the
retaining pivot -4- .
4.2. Push bellows -2- at the bottom forwards in the rear area.
Installation Location:
5. Unscrew fastening screws.
5.1. Unscrew fastening screws -3- on cover for sliding roof -1- .
Installation Location:
1. Move sunroof mechanism to the "roof closed" position.
3.1. Screw in fastening screws -3- and tighten so that the cover for the sliding roof can still be moved easily.
Installation Location:
7. Clip in bellows.
7.1. Clip in bellows -2- at the top and bottom in the front area.
3. Adjust height -Y- of cover for sliding roof at rear → Test and
adjustment value: 0 mm +1 mm
5. Tighten fastening screw M5 -3C- to specified tightening torque. → Tightening torque: 4.5 (3.5 ftlb.) Nm +/-
0.5 (0.5 ftlb.) Nm
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
– Remove roof joint cover strip → 663619 Removing and installing roof joint cover strip - section on
"Removing"
2.1. Pull off seal -1- on both sides of the vehicle, starting from the rear -Arrow A- .
2.2. Pull off seal -1- at the front edge of the roof assembly -Arrows B- .
Attaching seal
1.2. Attach seal to the sides of the roof assembly and press it down firmly.
The seal must engage in the roof assembly and must be flush at the rear edge.
2. Stick on seal.
Fitting seal
2.1. Carefully raise the front corners of the seal -Arrow C- and pull out
the protective film -2- on the adhesive tape backwards under the
seal -Arrow D- .
3. Close lid 1.
Sticking on seal
Subsequent work
Subsequent work
– Install roof joint cover strip → 663619 Removing and installing roof joint cover strip - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Removing headliner. → 708419 Removing and installing headliner - "Removing" section
Installation Location:
Overview of control unit for roof assembly (panoramic roof)
Note
After installation of the control unit, the limit stops for the motors must be re-initialised.
Subsequent work
1. Install headliner. → 708419 Removing and installing headliner - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Removing headliner. → 708419 Removing and installing headliner - "Removing" section
Note
The sun blind is pre-loaded by a spring mechanism. In order to be able to install the shade with the correct
preload, the shade must be secured against turning before removal.
2.1. Secure the drive shaft on the left side against turning with a suitable rig pin (Ø approx. 1 mm, e.g., shear-
off rivet). Insert the pin centred in the groove of the cover disk until it enters the shaft.
3.1. Unlock the lug on the lock with a screwdriver and press the locks toward the centre of the vehicle at the
same time.
3.2. Lift the locks up and out of the strip.
4.2. Swivel the shade strip downward -Arrow B- and unhook towards
the front -Arrow C- .
5. Release sun blind. Unclipping shade strip
5.1. Rotate retaining lock on
both sides by 90° and
unhook towards the rear.
6.1. Pull sun blind towards the rear and out of the guide rails and
remove it.
Note
The sun blind must be pre-tensioned before it is installed.
If the blind has not been secured against twisting when removed on the vehicle, or if the security for
transportation has come undone, the blind must be pre-tensioned before it is installed. → Preparing the sun
blind for installation
1.1. Fold pull strap inward by 90° and insert it into the guide rail.
2. Wind up sun blind.
3.1. Insert fastening mechanism for sun blind on both sides and turn it through 90°.
1.2. Fold the sun blind in clean protective film or paper and secure with
adhesive tape.
2. Release sun blind completely.
5. Secure the shaft on the left side against turning with a retaining pin.
Preloading the sun blind Fixing the sun blind
Subsequent work
1. Install headliner. → 708419 Removing and installing headliner - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Removing headliner. → 708419 Removing and installing headliner - "Removing" section
Installation Location:
Overview of motor for sun blind roof assembly (panoramic roof)
Note
Before installing motor, check the drive shafts for wear and abrasion.
Note
After installation of the motor, the limit stop for the roof assembly must be re-initialised in the control unit.
1. Insert motor -Arrow A- and engage drive pinion -a- by turning back
and forth -Arrows B- in the drive shaft -b- .
Installing motor
2. Screw down motor with fastening screws -arrows 1- . → Tightening torque: 4 (3 ftlb.) Nm If necessary,
align the cable carrier to the threaded bores -c- by turning back and forth -arrows C- .
Connecting plug connection
Installing motor
4. Push plug connection together -arrows B- until the locking lug
-arrow C- is felt to engage.
5. Initialise limit stop of motor for roof assembly in the control unit. → 60
Closing roof assembly (panoramic roof) with emergency operating
mechanism and initialising limit switch
Subsequent work
Subsequent work
1. Install headliner. → 708419 Removing and installing headliner - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
6.1. Release the electric plug connection -8- and pull off the connector -arrow C- .
1.1. Install bumper -11- and place it in roughly the correct position.
1.2. Screw in the fastening screws -9, 10- , tighten them slightly and check the position of the bumper.
1.3. Tighten fastening screws -9, 10- to the specified tightening torque.
→ Tightening torque: 1.5 (1 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm → Tightening torque: 65 (48 ftlb.) Nm +/-10
(7.5 ftlb.) Nm
2. Fasten lock support.
2.2. Screw in the fastening screw -3- , tighten it slightly, and check the position of the lock support with respect
to the bumper again.
3.1. Cayenne/Cayenne S:
Position side air guide -5- and secure with fastening screws -4- .
Tighten fastening screws -4- to the specified tightening torque. →
Tightening torque: 1.5 (1.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
6.1. → 214319 Removing and installing charge air cooler - chapter on "Installing" [9PAAF1 9PAAJ1]→ 214319
23 Removing and installing charge air cooler - chapter on "Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
5.2. Using a screwdriver lever the plug -16- upwards and then remove.
6.2. Pull off bulb holder -13- of the side direction indicator -12- on both sides.
1.3. Screw in fastening screws -14, 15- and tighten to the specified torque → Tightening torque: 2.0 ftlb. +/-
0.5 ftlb. → Tightening torque: 1.0 ftlb. +/-0.5 ftlb. .
2.3. Connect bulb holder -13- of the side direction indicator -12- on both sides.
2.5. Insert front apron -1- rearwards into the side guide rail.
3. Screwing in fastening screws and fitting plug.
3.1. Screw in fastening screws -5- and tighten to the specified torque →
Tightening torque: 2.5 ftlb. +/-0.5 ftlb. .
5.2. Screw in fastening screws -4, 6- and tighten to the specified torque → Tightening torque: 2.0 ftlb. +/-0.5
ftlb. → Tightening torque: 2.0 ftlb. +/-0.5 ftlb. .
6. Installing wheel housing liner
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Removing front apron
4.1. → Removing and installing spray nozzle for headlight washing system [9PAAF1 9PAAJ1]→ Removing
and installing spray nozzle for headlight washing system [9PAAD1 9PAAD7 9PAAE1 9PAAE7]
5. Removing logo
6.1. → 660419 Removing and installing front air grille - section on "Removing" [9PAAD1 9PAAD7 9PAAE1
9PAAE7]→ 660419 Removing and installing front air grille - section on "Removing" [9PAAF1 9PAAJ1]
7.1. → 660519 Removing and installing radiator grille - section on "Removing" [9PAAD1 9PAAD7 9PAAE1
9PAAE7]→ 660519 Removing and installing radiator grille - section on "Removing" [9PAAF1 9PAAJ1]
8.1. → 668319 Removing and installing number plate cover - section on "Removing" [9PAAD1 9PAAD7
9PAAE1 9PAAE7]→ 668319 Removing and installing number plate cover - section on
"Removing" [9PAAF1 9PAAJ1]
Installation Location:
Disassembling and assembling front apron
2.1. Pull out mounting points for ParkAssist sensors -3- ( -arrow B- ).
5.1. Unclip cover of the towing lug -10- with a screwdriver ( -arrow F- ).
Installation Location:
Disassembling and assembling front apron
1. Installing front spoiler
5.1. Push on the mounting points for ParkAssist sensors -3- ( -arrow F- ). The guide must be pointing upwards
( -arrow- ).
Subsequent work
1. Installing license plate cover
1.1. → 668319 Removing and installing number plate cover - section on "Installing" [9PAAD1 9PAAD7 9PAAE1
9PAAE7]→ 668319 Removing and installing number plate cover - section on "Installing" [9PAAF1 9PAAJ1]
2.1. → 660519 Removing and installing radiator grille - section on "Installing" [9PAAD1 9PAAD7 9PAAE1
9PAAE7]→ 660519 Removing and installing radiator grille - section on "Installing" [9PAAF1 9PAAJ1]
4. Removing logo
5.1. → Removing and installing spray nozzle for headlight washing system [9PAAF1 9PAAJ1]→ Removing
and installing spray nozzle for headlight washing system [9PAAD1 9PAAD7 9PAAE1 9PAAE7]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Removing rear apron
1.1. Insert rivet nuts in the bores and rivet with hand-held blind rivet nut device NR.125.
2. Installing rear bumper
3.1. Place a butyl sealing cord -4- on the underside of the foam part -5-
in the areas indicated.
4. Installing foam part
4.1. Place foam part -4- on the
rear bumper -1- in line with
the profile and press down
firmly.
Subsequent work
Subsequent work
1. Installing Kessy antennas or wiring harness
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
2. Remove spare wheel mount → Removing and installing spare wheel mount (frame)
Note
The figures showing the gap dimensions can be found in the chapter entitled → Diagram of gap dimensions.
1.1. Check expander nuts -6- for deformation and clip in new expander
nuts if necessary.
2. Attaching rear apron with an assistant
2.3. Insert rear apron -1- forwards into the side guide rail -arrows- .
4.1. Screw in fastening screws -2- and tighten to the specified tightening
torque.
→ Tightening torque: 3.5 ftlb. +/-0.5 ftlb.
5.1. Screw in fastening screws -2- and tighten to the specified tightening torque.
→ Tightening torque: 3.5 ftlb. +/-0.5 ftlb.
6. Installing stop buffer pad
6.2. Press stop buffer pad lug -15- into the bore of the holder with a suitable drift punch.
7. Screwing in fastening screw
Subsequent work
Subsequent work
1.3. If necessary, loosen fastening nuts -15- and adjust the gap
dimensions by moving the retaining strip.
→ Tightening torque: 1.5 ftlb. +/-0.5 ftlb.
Additional assembly notes for the removal and installation of the rear spoiler
1.1. Unscrew the fastening screw at the left -10- and right -10- .
1.2. Remove side guide rails at the left -12- and right -12- .
1.3. Check expander nuts on the left -11- and right -11- for deformation,
replace if necessary.
2. Removing centre retaining strip and retaining bracket
1.1. Clip in expander nuts on the left -11- and right -11- .
1.2. Position side guide rails on the left -12- and right -12- with the top side on a level with the side panel profile.
1.3. Screw in fastening screws on left -10- and right -10- .
→ Tightening torque: 1 ftlb. +/-0.5 ftlb.
3.4. If necessary, loosen fastening nuts -15- and adjust the gap
dimensions by moving the retaining strip -16- .
→ Tightening torque: 1.5 ftlb. +/-0.5 ftlb.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove rear spoiler. → 635519 Removing and installing rear spoiler - section on "Removing"
2. Remove sensors for ParkAssist. → 917519 Removing and installing sensor for ParkAssist – section on
"Removing"
3. Remove rear apron. → 635519 Removing and installing rear apron - section on "Removing"
Installation Location:
Note
Additional assembly operations must be performed on vehicles with externally fitted spare wheel.
Note
Do not loosen retaining clips by positioning the screwdriver between the retaining clips and fastening ribs of
the cover! Do not damage cover's fastening ribs!
Remove cover:
4. Push retaining clips -6- on the inside at the areas indicated ( -circle markings- ) as far as possible to one
side ( -Arrow D- ). Open up the retaining clips -6- using a screwdriver and remove them.
15. Disengage towing lug cover -15- ( -Arrows N- ) and remove it ( -Arrow O- ).
Assembling rear spoiler
Installation Location:
Install towing lug cover:
1. Place cover -15- in position and press down until locking tabs are heard to engage ( -Arrow A- ).
Install trailer hitch cover.
4. Position lower part -11- of rear apron -12- and push it in ( -Arrow E- ) until retaining pivots -10- are heard to
engage ( -Arrow F- ).
Install cover:
9. Press retaining clips -6- on the inside at the areas indicated ( -circle markings- ) firmly onto the fastening
ribs of the cover -5- ( -Arrow K- ).
10. Push on mountings for ParkAssist sensors -4- ( -Arrow L- ). The guide must be pointing upward ( -arrow- ).
12. Clip wire harness -2- into retaining clips -3- ( -Arrow N- ).
Additional assembly work for vehicles with externally fitted spare wheel
Installation Location:
Note
When removing the number plate cover, do not undo the retaining clips by positioning the screwdriver
between the retaining clip and the front end ribs of the number plate cover!
2. Undo fastening screws of number plate trim -2- (or -2- ).
3. Push retaining clips -3- on the inside at the areas indicated (
-circle markings- ) as far as possible to one side ( -Arrow A- ).
Open up retaining clips -3- with a screwdriver and remove them.
7. Release number plate light -7- ( -Arrow F- ) and press it out ( -Arrow G- ).
Installing number plate trim
Installation Location:
Install number plate light:
1. Insert number plate light -7- , swivel it back ( -Arrow A- )and press
down ( -Arrow B- ).
2. Press in number plate light -7- ( -Arrow C- ) until locking tab engages fully ( -Arrow - ).
3. Push on connector -6- until locking tabs are heard to engage ( -Arrow D- ).
6. Press new retaining clips -3- at the areas indicated on the inside ( -circle markings- ) firmly onto the
fastening ribs of the cover -1- ( -Arrow G- ).
Installation Location:
Remove cover of spare wheel mount:
1. Release locking tabs -2- from cover of spare wheel mount -1- ( -Arrow A- and disengage them (
-Arrow B- ).
2. Pull cover of spare wheel mount -1- forward and remove it ( -Arrow C- ).
Subsequent work
1. Install cover for spare wheel mount. → Removing and installing cover for spare wheel mount
2. Install rear apron. → 635519 Removing and installing rear apron - section on "Installing"
3. Install sensors for ParkAssist. → 917519 Removing and installing sensor for ParkAssist – section on
"Installing"
4. Install rear spoiler. → 635519 Removing and installing rear spoiler - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove trim strip for windscreen.→ 666119 Removing and installing trim strip for windscreen - section on
"Removing"
2. Remove cowl panel → 664419 Removing and installing cowl panel - section on "Removing"
3. Remove interior rear-view mirror.→ 682719 Removing and installing interior rear-view mirror - section on
"Removing"
3.1. Remove rain sensor in vehicles fitted with a rain sensor.→ 921219 Removing and installing rain sensor -
section on "Removing"
4. Remove A-pillar trim.→ 705719 Removing and installing A-pillar trim - section on "Removing"
5. Remove defroster trims. → 702019 Removing and installing dashboard cover (defroster trim) - section on
"Removing"
Technical values
Note
The figures showing the gap dimensions can be found in the section entitled → Diagram of gap dimensions.
Location Explanation Type Basic Tolerance Tolerance
value 1 2
Windscreen to outer roof -A- gap Gap 4 mm -1 mm
panel dimension
Windscreen to outer roof -B- installation Gap 3 mm
panel depth dimension
The following tools and materials are required for removing and installing the windscreen with 2-component
adhesive:
A - Double cartridge gun VAS 5237 - see Workshop Equipment Manual, Chapter 3.5
B - Suction cups VAG 1344 - see Workshop Equipment Manual, Chapter 3.5
C - Special electric cutter (fine) VAG 1561 A - see Workshop Equipment Manual, Chapter 3.5
D - Flashing knife, U-type 639.031.130.22; see Parts Catalogue, Main Group 8
H - 2-component window adhesive 000.043.300.94, contains set components H1-H8; see Parts Catalogue,
Main Group 8
H1 - Cleaning solution
H2 - Primer
H3 - Activator
H4 - Swab
H5 - Cartridge, component A
H6 - Cartridge, component B
H7 - Mixing nozzle
H8 - Processing nozzle
Removing windscreen
Removing windscreen
Installation Location:
DANGER
Danger of cut injuries when removing and installing car windows!
Always wear protective gloves when working on car windows.
Wear protective goggles when cutting out car windows.
Only replace the cutting knife with the power supply disconnected so that the cutter is not switched
on accidentally.
→ Cutting out glued car windows may lead to cut injuries to the skin and eyes due to flying glass splinters and
may result in cut injuries from the knife of the cutter.
1. Separate windscreen.
Note
The procedure for removing car windows is described in → General information on removing car windows.
1.1. When removing remaining adhesive -1- with the cutting tool -C- and
the flashing knife -D- on the body, ensure that a surface coating of
adhesive remains -2- .
Note
The surface coating of adhesive residue helps new adhesive to stick.
Keep cut surfaces clean and free of grease and do not clean with
cleaning solution.
2. Clean and prime paint damage or newly built-up paint areas in the
window aperture of the body.
2.1. Clean new paint areas or damage to the top coat paint in the non-
visible area of the glass section in the body with cleaning solution
-H1- and patch with primer -H2- .
Note
A ventilation period of at least 10 minutes must be observed between
the cleaning of the glass section and the application of the primer! No
cleaning solution residues may remain on the body.
Note
Only if the window is to be re-installed.
1.1. Fit cutting device -C- with the flashing knife -D- and remove the remaining adhesive from the windscreen,
ensuring that a surface coating of adhesive remains.
Note
The remaining adhesive helps new adhesive to stick. Keep cut
surfaces clean and free of grease and do not clean with cleaning
solution.
Note
Only if the window is to be re-installed.
2.1. During long idle periods apply activator -H3- to the remaining
adhesive.
Note
Only with new windscreens!
Note
A ventilation period of at least 10 minutes must be observed between
the cleaning of the glass and the application of primer! No cleaning Cleaning and priming the windscreen
solution residues may remain on the windscreen.
Installing windscreen
Installing windscreen
Installation Location:
Note
The removed windscreen can be reinstalled if there was no prior damage to the windscreen and the
windscreen was removed without damage.
ATTENTION
Danger of material damage if specified curing time of adhesive is not observed! In order to ensure that
the bonded joint is sufficiently strong, the following boundary conditions must be adhered to:
The vehicle must not be used until the curing time has elapsed.
Curing time: 3 hours
Temperature: at least 10 °C
Fixing time: approx. 1 hour
Note
Damaged retaining clips can only be replaced when the windscreen
has been removed.
Note
The adhesive has an open time of -15 min- , which means that the bonding material must be applied and the
car window must be assembled within this period of time.
4.1. Apply 2-component bonding material with the adhesive gun -A- to
the windscreen along the preliminary layer or on the primer as a
triangular bead measuring -X = approx. 15 mm- .
Note
When applying the adhesive, it is essential to ensure that the
adhesive bead overlaps by approx. 30 mm at the beginning and at
the end.
Note
Two persons are needed to insert and adjust the windscreen.
5.1. Apply suction cups -B- to the windscreen and insert the windscreen
into the window aperture. Position windscreen at the upper edge
and lay the lower rim on top of the adjusting elements.
6.2. Adjust the windscreen joint measurement by turning the eccentric in -direction of arrow- .
7.1. Adhesive which has oozed out must be removed immediately and
the affected fields of vision must be cleaned using cleaning agent
-H1- .
Subsequent work
1. Install A-pillar trim.→ 705719 Removing and installing A-pillar trim - section on "Installing"
2. Install defroster trims. → 702019 Removing and installing dashboard cover (defroster trim) - section on
"Installing"
3. Install interior rear-view mirror.→ 682719 Removing and installing interior rear-view mirror - section on
"Installing"
3.1. On vehicles fitted with a rain sensor, the rain sensor must be installed first.→ 921219 Removing and
installing rain sensor - section on "Installing"
4. Install cowl panel → 664419 Removing and installing cowl panel - section on "Installing"
5. Install trim strip for windscreen.→ 666119 Removing and installing trim strip for windscreen - section on
"Installing"
6. Clean windscreen
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Note
The following instructions describe the general procedure for removing car windows with the glass separating
tool VAG 1474 B.
Information on procedures relating to specific vehicles can be obtained from the instructions in the
corresponding chapters in the Technical Manual.
Note
It is generally possible to remove the windscreen with the cutting wire and the optional cutting thread
contained in the tool set.
In contrast to cutting threads, however, the cutting wire has the following disadvantages:
For the reasons outlined above we recommend using the cutting thread.
DANGER
Danger of cut injuries when removing and installing car windows!
Always wear protective gloves when working on car windows.
Wear protective goggles when cutting out car windows.
Only replace the cutting knife with the power supply disconnected so that the cutter is not switched
on accidentally.
→ Cutting out glued car windows may lead to cut injuries to the skin and eyes due to flying glass splinters and
may result in cut injuries from the knife of the cutter.
ATTENTION
Danger of paint damage and damage to the label with the vehicle identification number if windscreen is
removed incorrectly!
When cutting out the windscreen, ensure that the label with the vehicle identification number is not
damaged!
Note
In order to guarantee an optimum fastening intake grip, it is advisable to clean the inside of the glass before
removal.
Note
The film protects the damping mat against damage when removing the glass.
Note
In order to prevent damage, make sure that the vehicle identification number is completely covered by the
protective film when pushing through the adhesive bead.
3. Inserting cutting thread into the passenger compartment
3.1. Push through adhesive bead on the glass on the edge of the vehicle
identification number -C- with the awl -A4- from the inside to the
outside.
3.2. Pass cutting thread -B- through the eyelet on the awl -A4- .
Note
The cutting thread should be positioned under the rim as far as possible. The sealing lip must be raised
slightly in the upper part of the glass in order to pull the cutting thread through.
5.1. Attach the loose end of the cutting thread -B- firmly at a suitable point on the body with the fastening screw
-2- of a component (e.g. wiper motor fastening). To do this, unscrew the fastening screw, wind the cutting
thread -B- around the screw and tighten the fastening screw again.
6.2. Insert cutting thread -B- into the bore on the spooling device -A3- .
6.3. Attach cutting thread -B- firmly with the clamping screw -3- .
Note
The fastening force can be increased by moistening the fastening intake.
7.1. Position spooling device -A3- diagonally in the centre of the glass.
7.2. Press spooling device -A3- with the fastening intakes firmly against
the glass.
7.3. Fix fastening intake onto the glass by moving the actuating lever.
Note
The fastening force can be increased by moistening the fastening
intake.
9.3. Pull cutting thread through onto the other side of the fastening
intake.
9.4. Fix fastening intake onto the glass by moving the actuating lever.
Note
The fastening force can be increased by moistening the fastening intake.
10.2. Press deflection roller with fastening intake firmly against the glass.
10.3. Fix fastening intake onto the glass by moving the actuating lever.
10.4. Pass cutting thread over the deflection roller onto the spooling
device.
10.5. Separate glass by spooling the cutting thread on the spooling device
as far as point -P2- .
Note
The fastening force can be increased by moistening the fastening intake.
11.3. Press deflection roller with fastening intake firmly against the glass.
11.4. Fix fastening intake onto the glass by moving the actuating lever.
11.5. Pass cutting thread over the deflection roller onto the spooling
device.
11.6. Separate glass by spooling the cutting thread on the spooling device as far as point -P3- .
Note
The fastening force can be increased by moistening the fastening intake.
12.3. Pull cutting thread through onto the other side of the fastening intake.
12.4. Fix fastening intake onto the glass by moving the actuating lever.
Note
The fastening force can be increased by moistening the fastening intake.
13. Separating glass as far as P4
Note
The fastening force can be increased by moistening the fastening intake.
14.3. Press deflection roller with fastening intake firmly against the glass.
14.4. Fix fastening intake onto the glass by moving the actuating lever.
14.5. Pass cutting thread over the deflection roller onto the spooling
device.
14.6. Separate glass by spooling the cutting thread on the spooling device
as far as point -P5- .
15.1. Separate glass by spooling the cutting thread on the spooling device
as far as point -P6- .
Note
The power for separating the glass is weaker when the cutting thread is deflected to its maximum point. An
angle greater than 90° should be avoided.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Removing front door sub-frame
Installation Location:
Remove power window motor:
Installation Location:
1. Release electric connector -3- and pull it off ( -arrow A- ).
2. Unscrew fastening screws -2- and remove power window motor.
Installation Location:
Install door window:
1. Possible variants:
1.1. Single-sheet safety glass side window: fastening parts are to be fitted separately to the sliding pads
1.2. Laminated safety glass side window: fastening parts are already fitted to the side window
3. Guide in side window -6- and insert into fastening parts -4- .
5. Close fastening elements -4- ( -arrows C- ), screw in and tighten fastening screws -5- → Tightening
torque: 3.3 (2.5 ftlb.) Nm +/- 0.3 (0.2) Nm .
Subsequent work
Subsequent work
1. Installing front door sub-frame
1.1. → 573019 Removing and installing front door sub-frame - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
64 48 19 Removing and installing front window channel seal - as
of MY 2003
- Removing front window channel seal
- Installing front window channel seal
Installation Location:
1. Remove trim panel for mirror triangle.
1.1. Carefully lever out trim panel for mirror triangle -1- using plastic
wedge ( -arrows A- ) and pull forwards ( -arrow B- ).
2. Unclip mirror adjustment switch.
2.1. Unclip switch -2- out of trim panel for mirror triangle from behind ( -arrow C- ).
2.2. Unlock -3- and ( -arrow D- ) pull off the plug ( -arrow E- ).
2.3. Remove trim panel for mirror triangle.
3. Unscrew mirror.
3.2. Lift mirror -5- ( -arrow F- ) and unclip the retaining pivot -6- .
3.3. Carefully fold the mirror -5- with the connected cables downwards ( -arrow G- ).
5.1. Pull front window channel seal -8- at rear end ( -arrow I- ) - beginning from the sheetmetal flange -9- - in an
upward direction ( -arrow K- ).
Note
Make sure here that horizontal alignment is correct! -Arrow C- and -Arrow D-
1.1. Attach front window channel seal -8- at the front end ( -arrow A- ) - beginning at the sheetmetal flange -9- -
from above ( -arrow B- ).
3.1. Attach mirror -5- to window channel ( -arrow F- ) and fold upward
and inward ( -arrow G- ).
3.2. Press mirror -5- downward until the retaining pin -6- engages in the window frame.
4.2. Clip switch -2- into trim panel for mirror triangle -1- from front (
-arrow I- ).
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Türaggregateträger vorne ausbauen
Installation Location:
Removing front power windows
Installation Location:
Removing front power windows
1.1. Place the power window on the door unit carrier as shown. Make
sure the cable is in the correct position ( -arrow A- ).
1.5. Apply lubricant (grease) to the guide rails -2- and move sliding pads -5- manually.
Subsequent work
Subsequent work
1. Türfensterscheibe vorn einbauen
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Remove front door trim panel. → 705919 Removing and installing front door trim panel - "Removing" section
Note
When removing the door trim, plug 6 -5- on the window regulator motor is disconnected.
2. Press on the lock of the plugs -Arrows 2, 3 and 4- and remove the plugs.
Subsequent work
Subsequent work
Install front door trim panel. → 705919 Removing and installing front door
trim panel - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
Prior to starting with the removal, switch off the ignition and remove the ignition key.
1. Lever out the entire power window switch using a plastic spatula.
5. Make sure that the power window switch is positioned evenly on the gap.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Installation Location:
1. Remove holder.
1.1. Unscrew fastening screws -1- and remove holder -2- .
2. Remove power window motor.
2.2. Unscrew fastening screws -4- and remove power window motor -3-
.
3.2. Open -7- fastening parts ( -arrows B- ) and -8- remove side
window in a downward direction ( -arrows C- ).
Installation Location:
1. Install side window.
Possible variants:
Single-glazed safety glass side window: Fastening elements are to be fitted separately on the sliding pads
Laminated safety glass side window: Fastening elements are already fitted on the side window
1.2. Guide in side window -8- and insert into fastening parts -7- .
1.3. Manually close the side window -8- ( -arrows A- ) and, using
increased pressure, press it into and parallel with the guide in the
direction of the B-pillar ( -arrow B- ).
1.4. Close fastening elements -7- ( -arrows C- ), screw in fastening screws -6- and tighten. → Tightening
torque: 3.3 (2.5 ftlb.) Nm +/- 0.3 (0.5 ftlb.) Nm
2.1. Insert power window motor -3- , screw in fastening screws -4- and tighten to the specified tightening torque.
→ Tightening torque: 3 (2.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
2.2. Push in electrical plugs -5-
until they audibly engage (
-Arrow D- ).
3. Install holder.
3.1. Insert holder -2- for inside door handle, screw in fastening screws
-1- and tighten to the specified tightening torque.
→ Tightening torque: 6 (4.5 ftlb.) Nm +/- 0.6 (0.5 ftlb.) Nm
Subsequent work
Subsequent work
1. Install rear door sub-frame. → 583019 Removing and installing rear door sub-frame - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
ATTENTION
Danger of injury!
Before removing wiper arm, remove ignition key and switch off steering column switch.
5. -A- Using a plastic wedge, carefully unclip and remove the cover.
6. -B- Unscrew the two fastening nuts -5- for the wiper shaft. Hold the
rear window release and pull out the wiper shaft.
Installation Location:
Installation position
1. Lay out electric cable for the rear window release through the rear
window.
Note
Lay out electric cable behind the plastic guide of the rear window
release -arrow- .
Connecting plug
3. -B- Insert washers -6- , push in wiper shaft and screw tight using the fastening nuts -5- → Tightening
torque: 7.2 (5.5 ftlb.) Nm .
4. -A- Attach cover and press down until the clips engage.
5. Screw on fastening nut -4- and tighten → Tightening torque: 17 (13 ftlb.) Nm .
6. Activate wiper motor once and drive to end position. Then fit wiper arm -3- and secure with fastening nut -2-
Fitting wiper arm
Note
Before fitting the cap, check the retaining lugs of the cap for damage. The cap must be replaced in the event of
damage or if you have any doubts about it.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Remove lining for rear lid. → 708719 Removing and installing rear lid lining - chapter on "removing"
1. Install lower part -arrow- and tighten with fastening nuts -1- .
→ Tightening torque: 6 ftlb.
2. Push together plug connection -Arrows A- until the locking tabs -B-
are felt to engage.
3. Push in connector -arrow C- until the locking tabs -arrows D- are felt to engage.
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Note
To allow easier access to the pneumatic spring housing, the roof trim panel must be loosened slightly at the
back once the following parts have been removed.
1. Remove rear roof trim panel. → 708519 Removing and installing rear roof trim panel - section on
"Removing"
2. Remove D-pillar trim panel. → 706919 Removing and installing D-pillar trim panel - section on "Removing"
3. Remove rear grab handles left and right. → 683719 Removing and installing rear grab handles - section on
"Removing"
ATTENTION
When working on the pneumatic spring of the rear window, the following safety measures must be
observed, amongst others:
To remove the pneumatic springs, they must be in the idle state: rear window open.
After removal of pneumatic springs, the rear window must be secured against accidental closure.
Pneumatic springs must not be opened by force - extreme internal pressure.
Installation Location:
7. Loosen safety clips of pneumatic springs for rear window -4- at ball
sockets using a screwdriver and remove the clips.
8. Pull the pneumatic springs for the rear window -4- from the ball heads and remove.
3. Press pneumatic spring for rear window -4- onto the ball heads until
the safety clips are felt to engage.
4.1. Position cover -3- at the front, bend out slightly and insert into the
opening at the back.
4.2. Press cover down all the way round until the butyl seal of the cover
is touching the body evenly.
4.3. Check that the cover makes contact all the way round and is not
bending inwards.
5. Position and clip in deformation element -1- .
Subsequent work
Subsequent work
1. Install rear grab handles left and right. → 683719 Removing and installing rear door grab handle - chapter on
"installing"
2. Install D-pillar trim panel. → 706919 Removing and installing D-pillar trim panel - chapter on "installing"
3. Install rear roof trim panel. → 708519 Removing and installing rear roof trim panel - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
64 68 19 Removing and installing the rear window shaft seal - as
of MY 2003
- Removing the rear window shaft seal
- Installing the rear window shaft seal
Installation Location:
1. Opening the rear door window
1.1. Open rear door window -1- as far as possible ( -Arrow A- ).
2. Removing the rear window shaft seal
2.1. Release rear window shaft seal -2- beginning at the rear end (
-Arrow B- ) with a plastic wedge and pull it off from the sheetmetal
flange -3- in an upward direction ( -Arrow C- ).
Installation Location:
Note
Make sure here that horizontal alignment is correct! -Arrow C- and
-Arrow D-
1.1. Push rear window channel seal -2- , beginning at front end (
-Arrow A- ), onto the sheetmetal flange -3- from above (
-Arrow B- ).
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Removing rear door sub-frame
Installation Location:
Installation Location:
1. Removing power windows
1.1. Place the power window on the door unit carrier as shown. Make sure the cable is in the correct position (
-arrow A- ).
1.2. Clip in power window gear -3- in the door unit carrier.
1.3. Fix guide rails -2- with 2 rivets each -1- and rivet with the door unit carrier.
1.5. Apply lubricant (grease) to the guide rails -2- and move sliding pads -5- manually.
Subsequent work
Subsequent work
1. Installing rear door window
1.1. → 646019 Removing and installing rear door window - section on "Installing"
2.1. → 583019 Removing and installing rear door sub-frame - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Open rear door and lid.
2. Remove rear roof trim panel → 708519 Removing and installing rear roof trim panel - section on
"Removing".
3. Remove C-pillar trim → 706819 Removing and installing C-pillar trim - section on "Removing".
4. Remove D-pillar trim → 706919 Removing and installing D-pillar trim - section on "Removing".
5. Remove rear side trim panel → 700319 Removing and installing side trim panel for rear luggage
compartment - section on "Removing".
Installation Location:
1. Folding down roof lining
Note
Make sure that the roof cover does not buckle.
1.1. Carefully fold down roof lining -1- in the rear, side area (
-arrow A- ).
2.2. Push side window -3- outward in the lower area -arrows C- and
swivel it forward ( -arrow D- ).
2.3. Disengage connecting piece -6- of the side window trim strip -4- to
the roof trim strip -5- . To do this, first pull the side window down
slightly -arrow E- and then swivel it to the rear ( -arrow F- ).
3. Checking clips
3.1. Check fastening clips on the C-pillar -7- for damage; if necessary, replace them.
Installation Location:
1. Checking seals
1.1. Check rubber seal on the inside of the C-pillar decorative cover to ensure that it is fitted correctly and not
damaged; if necessary, replace it.
2.1. Engage connecting piece -6- of the side window trim strip -4- to the roof trim strip -5- . To do this, insert the
side window trim strip from the rear into the roof trim strip -arrow A- and press upward slightly (
-arrow B- ).
2.2. Swivel side window -3- to the rear in the lower area -arrow C- and push it inward ( -arrows D- ).
2.3. Insert side window -3- inward into the side window opening ( -arrow E- ).
2.4. Screw in fastening nuts -2- ( -arrow F- ) and tighten to the specified
tightening torque → Tightening torque: 4.5 (3.5) Nm .
Note
Make sure that the roof cover does not buckle.
3.1. Carefully fold up roof lining -1- in the rear, side area ( -arrow G- ).
Subsequent work
Subsequent work
1. Install rear handles at left and right → 683719 Removing and installing rear handle - section on "Installing".
2. Install rear side trim panel → 700319 Removing and installing side trim panel for rear luggage compartment -
section on "Installing".
3. Install C-pillar trim → 706819 Removing and installing C-pillar trim - section on "Installing".
4. Install D-pillar trim → 706919 Removing and installing D-pillar trim - section on "Installing".
5. Install rear roof trim panel → 708519 Removing and installing rear roof trim panel - section on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove rear spoiler → 665819 21 Removing and installing rear spoiler - section on "Removing".
Technical values
Note
The figures showing the gap dimensions can be found in the section entitled → Diagram of gap dimensions.
2.1. Ensure that the rear window does not fall with the help of a second
person.
Installation Location:
1. Positioning and fastening rear window
1.1. Position rear window -2- with the help of a second person.
1.3. Align rear window and adjust the joint measurements accordingly
→ Test and adjustment values.
Subsequent work
Subsequent work
1. Install rear spoiler → 665819 23 Removing and installing rear spoiler - section on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Open rear window
2.1. → 708719 Removing and installing rear lid lining - section on "Removing"
1.1. Remove the seal -1- from the circumference of the sheetmetal flange -arrows- .
2. Cleaning sheetmetal flange
1.1. Position new seal for rear window -1- with the connection point -2-
in the top centre part of the sheetmetal flange -3- . The bleeder
openings in the seal must point towards the inside of the vehicle.
3.1. Pay particular attention to the areas near the tight roundings for
correct installation; there must be no deformation or stretching.
3.2. Check the air vents; they must not be closed or covered.
Subsequent work
Subsequent work
1. Install rear lid lining
1.1. → 708719 Removing and installing rear lid lining - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove trim under instrument panel → 701919 Removing and installing trim under instrument panel -
section on "Removing".
Installation Location:
Installation Location:
1. Release the relay carrier -Arrow A- and pull it downward -Arrow B- .
Installation Location:
Installation Location:
1. Place the relay onto the relay carrier -Arrow- .
2. Press the relay carrier into the holder -Arrow A- until the locking tabs engage audibly.
Subsequent work
Subsequent work
1. Install brake light switch holder → 481519 Removing and installing steering column - section on
"Installing" [9PAAJ1]→ 481519 Removing and installing steering column - section on "Installing" [9PAAD1
9PAAD7]→ 481519 Removing and installing steering column - section on "Installing" [9PAAE1 9PAAE7
9PAAF1].
2. Install trim under instrument panel → 701919 Removing and installing trim under instrument panel - section
on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove front apron
Installation Location:
Installation Location:
1. Undo fastening screws -1- .
Installation Location:
Installation Location:
4. Removing retaining clips
Installation Location:
2. Pushing on retaining clips
2.1. Push on retaining clips -5- ( -arrow C- ).
Installation Location:
Subsequent work
1. Installing fog light
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove front apron
Installation Location:
1. Cut welded joint
1.1. Mill off welded joint on the inside of the air grille -1- using a suitable
taper cutter -4- .
2. Unclip air grille
2.1. Unhook locking hooks -5- of air grille -1- with a screwdriver.
2.1. Press air grille into front apron until all locking hooks -1- of air grille
-5- are felt to engage.
Note
When re-installing existing and fitting new components, the welded joint between the reinforcement -3- and
the front apron -2- can be omitted.
Subsequent work
Subsequent work
1. Installing front apron
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove front apron
Installation Location:
1. Separating welded joint
1.1. Mill off welded joint on the inside of the radiator grille -1- using a suitable taper cutter -5- .
2.1. Unhook locking hooks -4- of radiator grille -1- with a screwdriver.
Installation Location:
Note
When re-installing existing and fitting new components, the welded
joint between the reinforcement -3- and the front apron -2- can be
omitted.
1. Position the radiator grille.
Subsequent work
Subsequent work
1. Installing air grille
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove front apron
Removing logo
Removing logo
Installation Location:
1. Unscrewing fastening nuts
1.1. Unscrew fastening nuts -2- on logo -1- .
2. Removing logo
Installing logo
Installing logo
Installation Location:
1. Positioning rubber base
1.1. Position logo -1- on rubber base -3- and press into sealing lip all the
way round .
2. Positioning logo
Subsequent work
Subsequent work
1. Installing front apron
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The moulding is destroyed during removal.
2. Open door.
6. To protect from damage, mask painted surfaces along the top and
bottom edges.
7. Warm up adhesive tape residue off the cover and scrape off with an
assembly wedge.
1. Wipe the bonding areas on the cover and reverse side of the
moulding with cleaning alcohol.
3. Stick a strip of adhesive tape along the upper and lower edge of the
sealing surface.
4. Remove protective film from the adhesive strip.
6. Warm up moulding with a hot-air gun and press down evenly on the
cover.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Remove wheel cover
1.1. Heat up wheel covers -1- and -2- with a hot-air gun.
1.2. Lever off wheel covers -1- -2- from the body evenly all the way
round using an assembly wedge.
Installation Location:
1. Clean bonding area
1.1. Wipe off the fitting area with a cloth soaked in Isopropanol.
Note
The object and room temperature must be at least 18° C for bonding
the components.
2.1. Remove protective paper -B- from adhesive tape and align the wheel cover -1- with the gap between the
front spoiler and the wing.
2.2. Position the wheel cover -1- shifted back by a distance of
-C = 1.0 mm- with respect to the edge of the wing.
2.3. Press evenly and firmly on wheel cover in area of adhesive -1- with
the ball of your thumb.
Offset -C- of wheel cover on wing from centre of front apron gap. →
Offset: 1.0 mm
3.1. Remove protective paper -B- from adhesive tape and align the wheel cover of the front apron -2- to the
wing wheel cover -1- .
3.2. Position the wheel cover for the front apron -2- shifted back by a distance of -D = 2.5+-1 mm- with respect
to the edge of the wing cover -1- .
3.3. Press evenly and firmly with your hand on the area of the wheel cover where adhesive is applied -2- .
Gap -D- from wheel cover on wing to wheel cover on front apron → Gap dimension: 2.5 mm +/-1 mm
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The trim strip is damaged beyond repair during removal.
4. Insert an assembly wedge between the trim strip -1- and cover
-arrow- and lift off the trim strip.
7. Mask the top and bottom edges of painted surfaces with strips of adhesive tape to protect them against
damage -arrows- .
8. Heat up any remaining adhesive tape on the cover and scrape off using an assembly wedge.
Note
Only cleaning alcohol (isopropanol) may be used for cleaning. Other cleaning solutions can damage the plastic!
1. Clean adhesive surfaces on the cover and on the back of the trim
strip with cleaning alcohol.
3.1. Stick a strip of adhesive tape on the top and bottom edges of the
attachment surface.
4. Remove protective film from adhesive tape.
6. Heat up trim strip with a hot-air gun and press down evenly on the cover.
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
3. Insert a plastic wedge underneath the door cover -3- from above and lever off the cover -arrow- .
Installation Location:
1. Check fixing clips and replace if necessary.
1.1. Slide fixing clip -5- in direction of arrow out of the door cover.
1.2. Insert fixing clip -5- against the direction of the arrow into the door
cover.
4.1. Hook door cover -3- onto the door flange -arrow B- .
4.2. Swivel door cover -3- upwards -arrow A- and clip into place.
4.3. Make sure that the fixing clips click into place during installation.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
66 26 19 Removing and installing side step (skidpad) - as of MY
2003
- Removing side step (skidpad)
- Installing side step (skidpad)
Installation Location:
1. Removing step
Installation Location:
Installation Location:
Installation Location:
2. Removing rear, centre, and front step holders
2.1. Undo and unscrew fastening screws -4- (or -4- and -4- ).
2.2. Remove step holders -3- , -5- and -6- in the respective directions
(arrows ).
Installing side step (skidpad)
Installation Location:
Additionally note the information on retrofitting in the → "Technical Information: Take note of 09/03, running
board 6626".
Installation Location:
Installation Location:
Installation Location:
1. Installing rear, centre, and front step holders
1.1. Check blind rivet nuts -2- or -2- and -2- for mounting the step
holders to ensure that they are fitted correctly and not damaged; if
necessary, replace
1.2. Place and position step holders -3- , -5- and -6- on the body
(arrows ).
1.3. Screw in fastening screws -4- (or -4- and -4- ) and tighten to the
specified tightening torque. → Tightening torque: 19 ftlb. +/-1.8
ftlb.
2. Installing step
2.1. Place and position step -1- from below onto the step holders ( -arrow- ).
2.2. Screw in fastening screws -4- and tighten to the specified tightening torque. → Tightening torque: 19 ftlb.
+/-1.8 ftlb.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Open vehicle doors
Installation Location:
1. Unclipping rear sill cover
1.1. Unclip rear sill cover -2- in the sequence -a to c- as shown using an
assembly wedge and remove it.
2. Unclipping front sill cover
Installation Location:
1. Checking fastening clips
1.1. Check fastening clip -3- , replace if necessary.
2. Clipping in front sill cover
Subsequent work
Subsequent work
1. Install wing trim panel
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
66 36 19 Removing and installing roof joint cover strip - as of MY
2003
- Removing roof joint cover strip
- Installing roof joint cover strip
Installation Location:
Installation Location:
1. Removing roof joint cover strip
- Vehicles with panoramic roof
1.2. Unhook roof edging strip -1a- from the holding clip -5- and remove.
Installation Location:
Installation Location:
1. Checking thread of fastening nuts -4-
2.1. Check seals of the supports -3- for damage and cracks, replace where necessary. To do this, unclip the
supports -3- from the roof joint cover strip -1- .
3. Installing roof joint cover strip
- Vehicles with panoramic roof
3.1. Hook the roof edging strip -1a- onto the holding clip -5- and position it.
3.2. Screw in fastening screws -2- in the sequence -2A bis 2F- as shown and tighten to the specified tightening
torque.
→ Tightening torque: 9 (6.5) Nm +/-0.5 (0.5 ftlb.) Nm
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The trim strip is damaged beyond repair during removal.
6. Warm up adhesive tape residue on the cover and scrape it off with
an assembly wedge.
Note
Only cleaning alcohol (isopropanol) may be used for cleaning. Other cleaning solutions can damage the plastic!
1. Wipe the bonding areas on the cover and reverse side of the
moulding with cleaning alcohol.
3. Stick a strip of adhesive tape along the upper and lower edge of the
sealing surface.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
66 44 19 Removing and installing cowl panel cover - as of MY
2003
- Removing cowl panel cover
- Installing cowl panel cover
Installation Location:
1. Opening bonnet
3.1. Remove wiper arms -2- → 922519 Removing and installing wiper arm - section on "Removing".
Installation Location:
1. Positioning cowl panel cover
1.1. Insert cowl panel cover -3- in the radiator tank and align.
2.1. Engage cowl panel cover lug -3- in the retaining strip on the windscreen -5- -arrow- .
4.1. Install wiper arms -2- → 922519 Removing and installing wiper arm - section on "Installing".
5. Installing side cover
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Technical values
Installation Location:
1. Removing wheel cover
1.1. Heat up wheel covers -3- , -4- and -5- with a hot-air gun.
2. Removing adhesive residues
Installation Location:
1. Cleaning bonding area
1.1. Wipe off fitting area -A- with a cloth soaked in isopropanol.
Note
The object and room temperature must be at least 18° C for bonding
the components.
2.1. Remove protective paper -B- from adhesive tape and align the
wheel cover -3- with the gap between the rear apron and the side
panel.
2.2. Position the wheel cover -3- shifted back by -F = 1mm- with respect to the edge of the side panel and by
-E = 1mm- with respect to the edge of the door aperture.
2.3. Press evenly and firmly on the area of the wheel cover -3- where adhesive is applied with the balls of your
hands.
Note
The object and room temperature must be at least 18° C for bonding the components.
The components must be bonded for at least 24 hours before washing the vehicle.
3. Fitting the wheel cover to the rear apron
3.1. Remove protective paper -B- from adhesive tape and align the
wheel cover of the rear apron -4- to the wheel cover of the side
panel -3- .
3.2. Position the wheel cover for the rear apron -4- shifted back by a
distance of -G = 2.5 +- 1mm- with respect to the edge of the wheel
cover at the side -3- .
3.3. Press evenly and firmly with your hand on the area of the wheel
cover where adhesive is applied -4- .
Note
The object and room temperature must be at least 18° C for bonding the components.
The components must be bonded for at least 24 hours before washing the vehicle.
5. Fitting the wheel cover to the doors
5.2. Remove protective paper -B- from adhesive tape and align the
wheel cover of door -5- to the edge of the door and the wheel cover
of the side panel -3- .
5.3. Position the wheel cover of the doors -5- shifted back slightly with
respect to the edge of the door. There must be must be
-H = 5 +- 1 mm- between the door and the edge of the wheel cover
of the side panel -3- .
5.4. Press evenly and firmly with your hand on the area of the wheel
cover where adhesive is applied -5- .
Information
Installation Location:
Installation Location:
3. Fitting the wheel cover to the rear apron
3.1. Remove protective paper -B- from adhesive tape and align the
wheel cover of the rear apron -4a- to the wheel cover of the side
section -3- .
3.2. Position the wheel cover for the rear apron -4a- shifted back by a
distance of -J = 2,5 +- 1mm- with respect to the edge of the wheel
cover at the side -3- . There must also be -I = 2 mm - with respect
to the mudguard -6- .
3.3. Press evenly and firmly with your hand on the area of the wheel
cover where adhesive is applied -4a- .
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
66 47 19 Removing and installing moulding for rear lid - as of MY
2003
- Removing moulding for rear lid
- Installing moulding for rear lid
Installation Location:
1. Remove lining for rear lid. → 664819 Removing and installing rear lid
lining - chapter on "Removing"
2.2. Remove moulding -1- from lining for rear lid -2- ( -Arrow A- )
3. Remove adhesive strips from lining for rear lid
3.1. Remove adhesive strips -3- from lining for rear lid.
3.2. Remove any adhesive residue from lining for rear lid.
Installation Location:
Note
An example of a suitable spacer to use would be an electric line with an external diameter of a = 2 mm.
Five lengths of lead each approx. 40 mm long must be made up for this purpose. The lengths of lead are then
bent together in a U shape.
1. Install lining for rear lid. → 664819 Removing and installing rear lid lining - chapter on "Installing"
2. Stick on spacers.
2.1. Stick five suitable spacers -4- with a thickness of -a = 2 mm- onto the rear lid lining -2- with adhesive tape
-5- .
3. Affix adhesive strips to lining for rear lid
3.1. Cut two adhesive strips approx. 5 mm wide -3- and stick them on
the lining for the rear lid -2- .
3.2. Remove protective film from adhesive strips -3- .
5. Remove spacers.
5.1. Remove the affixed spacers -4- and the adhesive residue -5- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
66 48 19 Removing and installing lining for rear lid - as of MY 2003
- Removing lining for rear lid
- Installing lining for rear lid
Installation Location:
1. Heckfenster öffnen
2. Removing lining
2.1. Carefully pull lining -1- out of the support. If necessary insert a plastic wedge between rear window and
lining and lever the lining out.
3.1. Unscrew fastening screws -2- and carefully pull out lining support -3- under the rear window seal.
3.2. Press rubber sleeves -4- out of the lining support -3- .
Installing lining for rear lid
Installation Location:
1. Assemble and install the lining support.
1.1. Press rubber sleeves -4- into the lining support -3- .
1.2. Place lining support -3- on the position bolts -5- on the rear lid.
1.3. Screw in fastening screws -2- and check installation position of the lining support -3- in areas -arrow- and
-B- .
1.4. Tighten fastening screws -2- to the specified torque → Tightening torque: 3.5 ftlb. +/-0.5 ftlb. .
Note
Only on vehicles with reversing camera
Before disconnecting or connecting the plug connection, switch off
the ignition of the vehicle and remove the ignition key.
2.1. Insert connectors onto wire harness until they are felt to engage.
3.1. Place lining -1- with positioning sleeve -6- onto the position bolts -7-
.
3.2. Press lining onto the lining support and engage fastening clip -C- .
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Heat the rear lid
1.1. Heat rear lid in area of the logo using the hot-air gun v.a.g 1416.
2. Lift up the logo using a plastic spatula
2.1. Move a plastic spatula under the logo and lift it up.
Installation Location:
1. Mark the centre of the cover
1.1. Affix an adhesive strip of dimension -A- which can be written on approximately in the centre of the lid and
parallel to its edge. → Distance: 85 mm +/-1 mm
1.2. Determine the centre between the outer edges of the lid and mark
on the adhesive strip.
3.1. Determine the centre -M- between the outer edges of the number plate trim.
3.2. Align the logo using the adhesive tape marking and press it on firmly.
4. Pull the adhesive tape off the rear lid.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
The switch for the rear-view mirror is located on the mirror traingle on the driver's side.
2. -A- Unclip switch out of trim panel for mirror triangle from behind.
3. -B- Operate lock on plug using a screwdriver and pull off plug.
Note
The switch for the rear-view mirror is located on the mirror traingle on the driver's side.
1. -A- Push plug onto switch until it is felt to engage.
2. -B- Push switch into lining and clip it in.
3. Press the lining onto the door frames and insert it.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Remove side cover
1.1. Unclip side cover -1- from the sheetmetal clip -2- .
2.1. Starting at the bottom, insert a plastic wedge level the retaining clips -4- between the body and the trim
strip -3- .
2.2. Insert a screwdriver between the plastic wedge and the trim strip -3- .
2.3. Lever trim strip -3- upwards out of the retaining clips -4- .
Replacing damaged retaining clips
Installation Location:
1. Remove windscreen. → 641219 Removing and installing windscreen - chapter on "Removing"
2.1. Mask windscreen with adhesive tape -A- to protect it against damage in the area of the retaining clips.
2.2. Drill off rivet heads of the retaining clips with a drill ø 3.2.
Note
Damaged retaining clips can only be riveted in when the windscreen
has been removed.
3.1. Position retaining clips -4- on the A-pillar at the existing holes and
rivet on with blind rivets ø 3.2. Hand riveting tool for blind rivets
NR.124-1
2.1. Starting from the top, engage trim strip -3- in the retaining clips -4-
on the A-pillar.
4.1. Clip side cover -1- into the sheetmetal clip -2- of the A-pillar.
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
66 62 19 Removing and installing switch for trailer hitch - as of MY
2003
- Preliminary work
- Removing switch for trailer hitch
- Installing switch for trailer hitch
- Subsequent work
Preliminary work
Preliminary work
Installation Location:
Overview of switch for trailer hitch
1. Push switch onto the connector -arrow A- until the locking tabs -arrows B- are felt to engage.
Pushing switch onto connector
2. Position the switch parallel to the trim panel and -arrow A- until the locking tabs -arrows B- are felt to
engage.
Subsequent work
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove the spare wheel holder on vehicles with an externally fitted spare wheel. → 445619 Removing and
installing spare wheel mount (frame) - "Removing" section
Installation Location:
Overview of motor for trailer hitch
1. Cut open the bonded joint -Arrows A- with a knife -a- and remove the cover -Arrow B- .
4. Unscrew the fastening nuts -2- and remove the fastening screws -arrows 3- .
6. Turn the coupling head into extended position as far as the stop -arrow C- .
Note
Before installing the motor, grease the ball joint -a- and the thread of
the spindle with multi-purpose graphite grease.
Align the fastening flange -b- to the bore of the locking peg -c- .
3. Grease the locking pin with multi-purpose graphite grease for better adhesion, insert it into installation
position -arrow D- and push back the fastening flange -arrow E- .
4. Insert the fastening screws -Arrows 3- , screw on the fastening nuts -2- and tighten the motor. →
Tightening torque: 4.5 (3.5 ftlb.) Nm
5. Guide the joint into the prongs and insert the bottom -d- and top -e- spacer rings.
6. Apply medium-strength screw locking lacquer to the thread of the fastening pin -arrow 1- and screw in and
tighten the fastening pin -arrow 1- . → Tightening torque: 50 (37 ftlb.) Nm
After sticking on the cover, allow the adhesive to dry for about 60 minutes.
8. Apply adhesive -Arrows A- to the cover and stick on the cover -Arrow B- .
Note
After the motor is replaced, the limit stops must be re-initialised.
If the limit stops are not initialised, the two LEDs on the switch flash at the same time.
Sticking on cover
Once initialisation is completed successfully, the upper LED lights up in the retracted state, while the lower
LED is continuously lit in the extended state.
1. Extend the trailer hitch until the limit stop is reached and the motor switches off automatically. Keep the
switch pressed when doing this.
2. Retract the trailer hitch until the limit stop is reached and the motor switches off automatically. Keep the
switch pressed when doing this.
Subsequent work
Subsequent work
1. Install trailer hitch. → 669019 Removing and installing trailer hitch - "Installing" section
2. Fit the spare wheel holder on vehicles with an externally fitted spare wheel. → 445619 Removing and
installing spare wheel mount (frame) - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove rear roof trim panel. → 708519 Removing and installing rear roof trim panel - chapter on "removing"
2. Remove C-pillar trim panel. → 706819 Removing and installing C-pillar trim panel - chapter on "removing"
3. Remove D-pillar trim panel. → 706919 Removing and installing D-pillar trim panel - chapter on "removing"
4. Remove rear side trim panel. → 700319 Removing and installing side trim panel for rear luggage
compartment - chapter on "removing"
Installation Location:
2. To remove trim frame, unscrew fastening screws -4- and lift it off.
Installation Location:
1. To install trim frame, insert the trim frame -5- in the side window -6-
from outside -Arrow A- and position it.
3. Insert connecting piece -3- of trim strip for side window from above -Arrow B- and clip in retaining clips -1, 2-
.
Subsequent work
Subsequent work
1. Install side window.
→ 647519 Removing and
installing side window -
chapter on "installing"
4. Install D-pillar trim panel. → 706919 Removing and installing D-pillar trim panel - chapter on "installing"
5. Install rear roof trim panel. → 708519 Removing and installing rear roof trim panel - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
Carefully clean any dirt, grease, wax and other impurities off the fitting area of the body using isopropanol.
Wear clean gloves when affixing the film so that there will not be any visible fingerprints on the film.
Installation Location:
Affixing protective film for spoiler
Note
Do not touch the exposed bonding surface.
2.1. Hold protective film at the lower positioning guide and remove from
the film.
2.2. Place protection film for paintwork directly on the corner using the
top positioning guide and move it sideways to position it with
respect to the gap as shown in the sectional view.
Note
The parts must be allowed to bond for at least 24 hours before Sticking on protective film for spoiler
washing the vehicle.
2.4. Smooth out protective film over the full area and eliminate any air bubbles.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
1. Press glass of mirror on the outside inwards -arrow A- and pull out
on the inside -arrow B- .
2. Remove negative cable -C- and positive cable -D- from the heating foil.
1. Connect negative -A- and positive cable -B- to the heating foil.
2. Insert glass for mirror .
3. Press centre of glass -arrow- into the mirror until the glass engages
firmly in the adjustment mechanism.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Installation Location:
1. Fold back door mirror.
2. Press the retaining lug on the lower mirror housing -A- inwards and
pull mirror housing outwards -B- just until the retaining lug can no
longer engage in the mirror cover.
3. On the upper mirror housing, press the retaining lugs apart with a screwdriver -Arrow A- and remove upper
mirror housing towards the rear.
Note
To prevent paint damage, before removing the cover fold the mirror
forwards until it is felt to engage.
Installation Location:
1. Fold mirror base forward until it engages firmly.
2. Insert mirror housing cover -arrow A- and turn it towards the mirror base on the inside -arrow B- .
5. Insert lower mirror housing -Arrow A- until the retaining lugs engage firmly -Arrow B- .
7. Engage upper mirror housing in lower mirror housing -A- and fold toward mirror cover -B- until the retaining
lugs -C- lock with an audible click.
8. Secure centring clip on mirror base with a retaining lug.
9. Turn the centring clip -arrow- until the second retaining lug is felt to
engage on the mirror base.
Subsequent work
Subsequent work
1. Install mirror glass. → 667819 Removing and installing mirror glass - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
2.2. Heat up wheel cover (junction piece) -2- with a hot-air gun.
2.3. Lever off junction piece -2- from the body evenly all the way round using an assembly wedge.
3. Remove adhesive residues.
3.1. Remove adhesive residue in the assembly area -A- with an erasing
disc. Erasing disc NR.174
Erasing disc
Installing mud flaps
Installation Location:
Note
As a replacement for Isopropanol cleaning agents 000 043 157 00 can
be used.
1.1. Wipe off the fitting area -A- with a cloth soaked in isopropanol.
Note
The object and room temperature must be at least 18° C for bonding
the components.
4.1. Remove protective paper -B- from adhesive tape and align wheel
cover -2- to the mud flap -1- .
4.2. Position wheel cover -2- with an offset of -K- from edge of mud flap.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
66 82 19 Removing and installing mirror adjusting motor - as of
MY 2003
- Preliminary work
- Removing mirror adjusting motor
- Installing mirror adjusting motor
- Subsequent work
Preliminary work
Preliminary work
Remove mirror glass. → 667819 Removing and installing mirror glass - "Removing" section
Installation Location:
Overview of mirror adjustment motor
Plugging in connector
2. Install and screw down mirror adjustment motor -arrows- .
Subsequent work
Subsequent work
Install mirror glass. → 667819 Removing and installing mirror glass - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
66 83 19 Removing and installing number plate cover - as of MY
2003
- Removing number plate cover
- Installing number plate cover
Installation Location:
1. Remove number plate cover.
1.1. Unscrew fastening screws -2- and remove holder -1- ( -Arrow A- ).
Note
Additional assembly operations → 668323 Removing and installing number plate - chapter on "installing"
must be performed in the following circumstances:
For vehicles in U.S. states that require a number plate at the front of the vehicle.
When replacing the front spoiler, since the replacement part is supplied without bores.
1.1. Position device carrier -1- ( -Arrow A- ) and screw down with fastening screws -2- .
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
66 83 23 Installing number plate cover - as of MY 2003
- Installing number plate cover
Installation Location:
Note
The following description only applies to states in the USA in which a license plate is required at the front of
the vehicle.
1. Affix an adhesive strip which can be written on -3- approximately in the centre of the front apron .
2. Determine the centre between the vertical shafts on the ventilation grid and mark on the adhesive strip on
the front apron.
3. Approximately in the centre of the number plate trim -1- , affix an adhesive strip which can be written on -4- .
4. Determine the centre between the outer edges of the number plate trim and mark on the adhesive strip on
the number plate.
5. Position number plate trim -1- on the contour of the front apron -A-
and align with the help of the adhesive tape markings.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Remove front door trim. → 705919 Removing and installing front door trim - chapter on "Removing"
3. Unclip wiring harness with a loosening lever disassembly tool, universal NR.21 -Arrows A- and detach
one side of the adhesive felt -Arrow B- .
Installation Location:
1. Attach mirror to window channel -Arrow A- and fold upward and inward -Arrow B- .
2. Press mirror Spiegel downward until the retaining pivot -C- engages in the window frame.
3. Screw down mirror on door frame -1- . → Tightening torque: 10 (7.5
ftlb.) Nm
4. Clip wiring harness onto door inner panel -Arrow A- and fasten with
adhesive felt -Arrow B- .
5. Fit connector to power window motor -Arrow A- and press in until the
locking tab -Arrow B- is felt to engage.
6. Install door trim panel. → 705919 Removing and installing front door
trim - chapter on "installing"
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove rear spoiler. → 635519 Removing and installing rear spoiler - chapter on "removing"
Note
Only for vehicles with Kessy.
2. Remove Kessy antennas at rear. → 966719 Removing and installing Kessy antenna - chapter on
"Removing"
3. Remove socket for trailer hitch. → 972419 Removing and installing wiring harness for removable trailer hitch
- chapter on "Removing"
For vehicles with trailer hitches that can be lowered electrically or with externally fitted spare wheel,
additional assembly operations → 669019 Removing and installing trailer hitch must be performed.
Installation Location:
Removing and installing trailer hitch
2.1. Unclip wiring harness -3- from fixing clips -4- ( -arrows B- ).
Installation Location:
Note
Only when replacing trailer hitch on vehicles with externally-fitted spare wheel.
1. Fit rivet nuts for lock support - only when replacing trailer hitch on vehicles with externally-fitted spare wheel.
1.1. Insert rivet nuts into the bores of the lock support and rivet using blind rivet nut manual device NR.125.
2. Install trailer hitch.
2.3. Screw in new fastening screws -5- (or -5- ) and tighten to specified
torque. → Initial tightening: 100 (74 ftlb.) Nm → Final
tightening: +90 °
4.1. Place a butyl sealing cord -7- on the underside of the foam part -2- in the areas shown.
Removing and installing wiring harness in vehicles with trailer hitch that can be lowered
electrically
Installation Location:
1. Pull off connector from servomotor.
2.1. Pull out trailer hitch until the wiring harness -2- is accessible.
2.2. Unclip wiring harness -2- from fixing clips -3- ( -Arrows C- ).
Removing and installing foam part in vehicle with externally fitted spare wheel
Installation Location:
Subsequent work
Subsequent work
Note
Only for vehicles with Kessy.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
66 92 19 Removing and installing the roof transport system - as of
MY 2003
- Installing the roof transport system
- Removing the roof transport system
Installation Location:
DANGER
Danger of accident (death/danger to yourself and/or other road users) as a result of losing the Roof
Transport System or individual add-on modules.
Regularly check the Roof Transport System and add-on modules before each journey and during an
extended journey to ensure it is seated correctly and securely on the vehicle.
ATTENTION
Damage to the vehicle roof and/or Roof Transport System due to dirty guide rails (vehicle roof and/or
Roof Transport System) or due to improper assembly/disassembly of the Roof Transport System.
Before fitting the Roof Transport System, check the cleanliness of both guide rails on the vehicle
roof, and if necessary, remove foreign objects and clean with soapy water.
Check all four feet of both carriers for cleanliness and clean as necessary.
With extreme caution, carefully insert or remove the support feet of the Roof Transport System in the
guide rails on the vehicle roof.
If necessary, obtain the assistance of a second person to fit and remove the roof rack.
Note
The key of the Roof Transport System can be removed only when the lock barrel to the cap is horizontal.
Opening and closing of the cap is only possible when the lock barrel is vertical. When the roof rack is
removed, the pawl must also be actuated so that the lid can be closed.
The Roof Transport System can only be fitted on the vehicle roof when the cap is opened.
1.1. Insert the key -3- into the lock cylinder and turn the key to the
vertical position ( -arrow A- ).
1.2. Grasp the projecting upper edge of the cap -2- and open the cap
downwards ( -arrow B- ).
1.3. Turn the key to the horizontal position and pull it out of the lock
cylinder.
1.4. Open all caps as described above.
2. Insert the roof rack into the cutout of the guide rail.
Note
When the rack has been fitted correctly, the larger radius of the rack
tube must face forwards in the direction of travel.
2.1.
2.2. Align the carrier -1- in the direction of travel of the vehicle as
indicated by the vehicle symbol on the cap.
2.3. Grasp the carrier -1- at one end and position it slanted over the vehicle roof.
2.4. Insert the plastic pads on the underside of the carrier foot which is towards you -4- into the large cutout in
the guide rail in the area of the B-pillar ( -arrow A- ).
2.5. Lower the opposite carrier foot carefully down to the vehicle roof until the plastic washers of the opposite
carrier foot are completely in the guide rail ( -arrow B- ).
3.1.
Note
The cap can only be closed when the lock barrel is positioned
vertically.
5.1.
5.2. Fold up the cap -2- on the end of the carrier -1- .
5.4. By gently pulling on the cap -2- check that it is closed correctly.
Installation Location:
Note
The steps for removing the Roof Transport System are the same as those to install it, but in reverse order.
1. Unlock carrier.
4.1. Press down the pawl -5- on the inside of the carrier feet and keep it depressed ( -arrow A- ).
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
66 94 19 Removing and installing covers for pillars - as of MY
2003
- Removing cover for pillars and retaining clip for cover
- Installing retaining clip for cover and cover for pillars
Installation Location:
1. Open front and rear doors.
2. Remove cover.
2.1. Unclip cap -1- on the cover -3- with a plastic wedge and remove it (
-Arrow A- ).
2.2. Release fastening screws -2- from the cover -3- and unscrew them ( -arrow B- ).
2.3. Pull bottom of cover -3- slightly outwards -arrow C- and then slide down -arrow D- until upper latch -4- is
pulled out of retaining clip -5- of B-pillar.
Installation Location:
1. Remove covers for pillars.
1.1. → 669419 Removing and installing covers for pillars - chapter on "removing"
2.1. Loosen fastening screws -6- on retaining clip -5- and unscrew (
-Arrow A- ).
Installation Location:
1.1. Place and position retaining clip -5- on B-pillar from the outside ( -Arrow A- ).
1.2. Screw in fastening screws -6- on retaining clip -5- -Arrow B- and tighten to the specified tightening torque.
→ Tightening torque: 2 (1.5 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
2.1. → 669419 Removing and installing covers for pillars - chapter on "installing"
Installing covers for pillars
Installation Location:
1. Check seals.
1.1. Check rubber seals on inside of B-pillar trim cover for correct fitting and damage, and replace if necessary.
2. Install cover.
2.4. Screw in fastening screws -2- of cover -3- -arrow E- and tighten to
the specified tightening torque. → Tightening torque: 2 (1.5 ftlb.)
Nm +/-0.5 (0.5 ftlb.) Nm
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Remove side trim panel on the right for rear luggage compartment. → 700319 Removing and installing side trim
panel for rear luggage compartment - "Removing" section.
WARNING
Risk of destruction of electrical and electronic components!
Installation Location:
Overview of control unit for trailer hitch
2. Unscrew the fastening screw -arrow 1- and lift the control unit up and out -arrow C- .
1. Insert control unit into the holder -arrow A- and screw in the fastening
screw -arrow 1- .
Note
After the trailer coupling control unit has been replaced, the coding must be customised to the vehicle
equipment so that the control unit knows which trailer coupling is installed and which functions are desired or
necessary.
Automated folding/pivoting is synonymous with comfort closing in power windows. Touching the button is
sufficient to fold/pivot the trailer hitch. → 669619 Removing and installing control unit for trailer hitch -
"Information" section.
The No automatic folding/pivoting option can be coded if there are doubts about safety. The button then must
be kept pressed until the trailer hitch is completely retracted or extended. → 669619 Removing and installing
control unit for trailer hitch - "Information" section.
With or without operating button; the operating button must be activated for the pivoting trailer hitch. This is of
course not necessary for the detachable towbar.
Versions or equipment features can be read out and reactivated under the Coding menu item.
Operating pushbutton:
Version:
Country:
RoW
USA (North America)
By actuating the F8 button the code is memorised. Where necessary erase fault memory.
Note
If the coding does not match the vehicle equipment, faults may be displayed that are not really present.
The control unit does not function without a valid coding entry.
Information
Permissible combinations
Note
Ensure that only permitted combinations and existing versions are coded.
USA/North RoW
Trailer hitch: Versions
America
With detachable trailer hitch 1 2
With automatic pivoting/folding - 3
Without automatic pivoting/folding - 4
Subsequent work
Subsequent work
Install the side trim panel at rear right. → 700319 Removing and installing side trim panel for rear luggage
compartment - "Installing" section.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
68 05 19 Removing and installing inner door sill trim - as of MY
2003
- Removing inner door sill trim
- Installing inner door sill trim
Installation Location:
Note
In order to reduce the unclipping forces and thereby the risk of damage during removal, the process must
take place at the accessible connection points using a suitable tool.
1. Remove B-pillar trim panel. → 706719 Removing and installing B-pillar trim panel - "removing" chapter
5.1. Unhook marking mandrel -5- for inner door sill trim -1- from inner B-
pillar.
Installation Location:
1. Check clips.
Installation Location:
Installation Location:
2. Clip in the inner door sill trim.
2.1. Insert inner door sill trim -1- in area of overlap under rear side trim
pane -6- .
5. Clip in trim.
5.1. Clip front trim -2- into scuff plate from rear to front.
6. Install B-pillar trim. → 706719 Removing and installing B-pillar trim - Chapter on "Installing"
Installation Location:
1. Remove trim strip for dashboard on passenger's side. → 705819 Removing and installing trim strip for
dashboard on passenger's side - removing
2. Remove cover under dashboard on the passenger's side. → 702219 Removing and installing cover under
dashboard - chapter on "Removing"
3. Remove glove compartment → 681519 Removing and installing glove compartment - chapter on
"Removing"
4.2. First swivel lock -2- to the right -Arrow A- and then to the front (
-Arrow B- ).
4.3. Remove lock -2- with actuating cable -3- and lock bolt -11-
rearward through the dashboard mounting ( -Arrow C- ).
Installation Location:
1. Remove glove compartment → 681519 Removing and installing glove compartment - chapter on
"Removing"
2. Remove glove compartment lock. → 681119 Removing and installing glove compartment lock - chapter on
"Removing"
Installation Location:
4. Remove actuating cable from lock bolt.
4.1. Compress fastening clips -8- of cap -9- towards centre -arrows E-
and remove cap.
4.2. Detach cable -6- from actuating lever -12- . To do this, swivel the cable by approx. 90° to the assembly
opening of the actuating lever -arrow F- and remove it in an upward direction.
4.3. Compress fastening clips of cable mounting -10- on lock bolt -11- -arrows G- and pull the mounting out of
holder ( -arrow H- ). Remove actuating cable on the lock catch bolt.
Installation Location:
1. Remove glove compartment → 681519 Removing and installing glove compartment - chapter on
"Removing"
2. Remove glove compartment lock. → 681119 Removing and installing glove compartment lock - chapter on
"Removing"
3. Remove actuating cable from lock. → 681119 Removing and installing glove compartment lock - chapter on
"Removing"
4. Remove cover.
4.1. Unclip cover -1- from lock mount -2- using a small screwdriver -3-
and lift off ( -arrow A- ).
ATTENTION
Danger of material damage in the event of incorrect removal and
installation of lock cylinder .
In the event of incorrect removal and installation, the lock
cylinder can be damaged.
→ The ignition key must not be withdrawn from the lock cylinder when
removing the lock cylinder from or installing it into the lock, as
otherwise the spring-loaded locking elements will spring out of the
lock barrel.
→ If the ignition key is withdrawn with the lock cylinder removed, the
locking elements must be held in on both sides with the fingers until
the ignition key is fully out of the lock cylinder. The locking elements
can then be carefully relaxed and the lock cylinder laid down.
→ Lock cylinders supplied as spare parts are secured in a transport
case.
5.1. Fully insert ignition key -4- into lock cylinder -5- -arrow B- . This
locks the locking elements -8- in the lock cylinder.
5.2. Turn ignition key -4- counter-clockwise as far as possible -arrow C- and hold the pretension. This keeps
the ignition key tensioned in the lock barrel so that it cannot be withdrawn.
5.3. Force retaining clips -6- of lock cylinder -5- outwards with a small
screwdriver ( -arrows D- ).
Installation Location:
1. Install actuating cable on lock. → 681119 Removing and installing glove compartment lock - chapter on
"installing"
Note
Once it is fitted correctly on the dashboard mounting, the lock can no longer be moved vertically or to the left or
right.
2.1. Insert lock bolt with actuating cable from the front through the dashboard mounting.
2.2. Insert lock -2- into dashboard mounting -13- -arrow A- and align it
until it is resting evenly against the mounting.
2.3. Push lock as far as possible to the left -arrow B- until retaining lugs -15- of lock reach into dashboard
mounting -13- on left side.
Installation Location:
1. Install actuating cable on lock.
1.1. Insert traction cable -6- through holder of actuating cable -13- on
lock ( -arrow A- ).
1.2. Insert actuating cable -3- on holder -13- of lock ( -arrow A- ). The fastening clips -4- of the traction
mounting must engage audibly into the lock holder.
1.3. Attach cable -6- to the assembly opening of actuating lever -7- from above -arrow B- and swivel to the
actuating cable holder -13- on the lock ( -arrow C- ).
2.1. Insert traction cable -6- through holder of actuating cable -14- on lock bolt ( -Arrow D- ).
2.2. Insert actuating cable -3- on holder -14- of lock bolt ( -Arrow D- ). The fixing clips -10- of the traction
mounting must engage audibly into the lock bolt holder.
2.3. Turn actuating lever -12- to the stop in direction of actuating cable holder -14- ( -Arrow E- ).
2.4. Attach cable -6- to the assembly opening of actuating lever -12- from above and swivel to the actuating
cable holder -14- on the lock bolt ( -Arrow F- ).
3. Position cap -9- on the lock bolt -11- from above and press in. The
fixing clips -9- of the cover must engage audibly.
→ The ignition key must not be withdrawn from the lock cylinder when removing the lock cylinder from or
installing it into the lock, as otherwise the spring-loaded locking elements will spring out of the lock barrel.
→ If the ignition key is withdrawn with the lock cylinder removed, the locking elements must be held in on both
sides with the fingers until the ignition key is fully out of the lock cylinder. The locking elements can then be
carefully relaxed and the lock cylinder laid down.
→ Lock cylinders supplied as spare parts are secured in a transport case.
Installation Location:
1.1. Fully insert ignition key -4- into new lock cylinder -5- ( -Arrow A- ).
5. Press lock cylinder -5- into the lock -2- until the retaining clips -6- of
the lock cylinder audibly engage.
6. Pull out ignition key -4- from lock cylinder -5- ( -Arrow B- ).
7. Install cover.
7.1. Position cover -1- on the lock carrier -2- and press in -Arrow C-
until the retaining clip audibly engages.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove trim strip for dashboard on passenger's side. → 705819 Removing and installing dashboard trim
strip - chapter on "Removing"
Installation Location:
1. Remove glove compartment.
1.2. Open glove compartment -1- , unscrew the fastening screws -4- and remove rubber buffer -3- .
1.3. Carefully pull out glove compartment -1- ( -arrow A- ) until the plug -5- can be removed.
1.4. Remove -5- plug -arrow C- , swivel out glove compartment -1- in a downward direction -arrow B- and
remove it towards the rear -arrow A- .
2.2. Pull off hose -7- for glove box air-conditioning system -arrow E- .
Installation Location:
1. Connect plug and hose.
1.2. Push through lock catch bolt -8- from the rear -arrow B- .
1.4. Push on the plug -6- until the locking tabs engage audibly -arrow D- .
1.5. Push on hose -7- for glove box air-conditioning system -arrow C- .
2.1. Swivel in glove compartment -1- in a downward direction -arrow F- and push it in carefully -arrow G- , until
the plug -5- can be connected.
2.2. Connect -5- plug -arrow E- , until the locking tabs engage audibly and then push in glove compartment -1-
completely -arrow G- .
2.4. Screw in fastening screws -2- in the sequence -2a to 2c- as shown and tighten to the specified tightening
torque. → Tightening torque: 1.4 (1.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
2.5. Open glove compartment lid.
2.6. Insert rubber buffer -3- and screw in fastening screws -4- in the sequence shown -4d to 4e- and tighten to
the specified tightening torque. → Tightening torque: 1.4 (1.0 ftlb.) Nm +/-0.2 (0.2 ftlb.) Nm
2.7. Close glove compartment lid.
2.8. Fastening screws -2f and 2g- must be screwed in until they just make contact.
2.9. Set gap for glove compartment lid by moving at the fastening points -2f and 2g- .
2.10. Tighten fastening screws -2- in the sequence shown -2f and 2g- to the specified tightening torque. →
Tightening torque: 1.4 (1.0 ftlb.) Nm +/-0.2 (0.2 ftlb.) Nm
Subsequent work
Subsequent work
1. Install cover under dashboard on the passenger's side. → 702219 Removing and installing cover under
dashboard - chapter on "Installing"
2. Install trim strip for dashboard on passenger's side. → 705819 Removing and installing dashboard trim strip
on passenger's side - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove cover for centre console → Removing centre console cover [9PAAD1 9PAAE1 9PAAF1 9PAAJ1]
→ Removing centre console cover [9PAAD7 9PAAE7].
2. Only for vehicles with corresponding I number: remove control unit for auxiliary air conditioner → 884819
Removing and installing control unit for auxiliary air conditioner - section on "Removing".
Installation Location:
1. Remove covers and cupholder.
1.3. Push cupholder -3- upwards and unclip from the centre console.
2. Remove socket or cigarette lighter
- only vehicles with the relevant I number.
2.2. Unclip and remove socket or cigarette lighter -4a- from the centre console.
2.3. Disconnect the plug connections.
Installation Location:
2.1. Screw in fastening screws -11- and tighten to the specified tightening torque.
→ Tightening torque: 8 (6 ftlb.) Nm +0.8 (0.5 ftlb.) Nm
2.3. Push on the plug -15- until the locking tabs engage audibly.
3. Fasten the centre console in the centre.
3.1. Screw in fastening screws -9- and tighten to the specified tightening
torque. → Tightening torque: 6 ftlb. +0.5 ftlb.
4. Tighten the centre console at the front.
4.1. Screw in fastening screws -8- and tighten to the specified tightening
torque. → Tightening torque: 6 ftlb. +0.5 ftlb.
4.2. Clip in covers for grab handles -7- .
Installation Location:
5. Make the plug connection.
5.2. Slide in the antennae for Kessy -12- towards the front and insert.
6.2. Clip the socket or cigarette lighter -4a- into the centre console.
6.3. Screw in fastening screws -5- and tighten to the specified tightening torque. → Tightening: 2 (1.5 ftlb.)
Nm +0.5 (0.5 ftlb.) Nm .
7.1. Clip covers -2, 4- and cupholder -3- into the centre console.
Subsequent work
Subsequent work
1. Only for vehicles with corresponding I number: install regulator for rear seat heating. → 742619
Removing and installing regulator for rear seat heating - section on "Installing".
2. Only for vehicles with corresponding I number: install control unit for auxiliary air conditioner. → 884819
Removing and installing control unit for auxiliary air conditioner - section on "Installing".
3. Install cover for centre console → Installing centre console cover [9PAAD1 9PAAE1 9PAAF1 9PAAJ1]
→ Installing centre console cover [9PAAD7 9PAAE7].
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
If the lid cannot be opened, the lid release can be removed using a stop-gap measure. → Emergency operation
of release
In vehicles with phone handsets in the armrest, the entire armrest must be replaced. → 681737 Removing and
installing armrest for centre console
Installation Location:
Removing and installing armrest release
Opening cover
2. Pull off cap -2- and unscrew fastening screws -3- .
4. Remove release.
4.1. Press lower release button -arrow A- and pull release -1- upwards -arrow B- to remove it.
3.1. Insert a screwdriver into armrest at the rear between the bottom half and the hinge -arrow C- and lever out
the rear clip connection -7- .
3.2. Insert an assembly wedge into armrest between the bottom half and the shelf tray -arrow D- and lever out
Unclipping shelf Unscrewing fastening screws
Unclipping shelf
Installation Location:
Removing bottom half
Note
Only on centre consoles in which the release was removed using the stop-gap measure.
1. Place bottom half in position and screw in tightening screws -6- . → Tightening torque: 8 (6 ftlb.) Nm
Clipping in shelf
5. Screw in fastening screws -3- position caps -2- . → Tightening torque: 2 (1.5 ftlb.) Nm
6. Press release buttons to check the release function.
Closing cover Screwing in fastening screws
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove control unit for auxiliary air conditioner → 884819 Removing and installing control unit for auxiliary
air conditioner - section on "Removing".
2. Remove cup holder and socket → 681719 Removing and installing centre console - section on "Removing".
Installation Location:
Removing and installing damper for armrest on centre console
Note
Before unhooking the damper, secure the oddments tray and prevent it from closing.
Unclipping safety clip
3. Unhook both dampers -3- ( -Arrow C- ).
Unhooking dampers
4. Unscrew fastening screws -3- ( -Arrow A- ).
Installation Location:
Removing damper
1. Position damper -1- ( -Arrow G- ) and turn it so that it locks into position -Arrow F- .
2.1. Position securing frame at the guide tabs -Arrow E- and swivel it downwards and into place -Arrow D- .
Positioning securing frame Inserting damper
2.2. Insert the locating pins on
both sides of the securing
frame into the bores on the
centre console -Arrow C- .
Hooking in dampers
6. Clip in safety clip -4- on both dampers -Arrow B- .
Clipping in safety clip
Subsequent work
Subsequent work
1. Install rear centre console cover → 681737 Removing and installing centre console cover - section on
"Installing".
2. Install control unit for auxiliary air conditioner → 884819 Removing and installing control unit for auxiliary air
conditioner - section on "Installing".
3. Install cup holder and socket → 681719 Removing and installing centre console - section on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Installation Location:
Removing and installing rear cover for centre console
3. Screw out screws at the top -3- and remove them -Arrow C- .
Removing cover
Installation Location:
Positioning cover
2. Clip in cover at the bottom -Arrow D- .
3. Insert and screw in screws at the top -3- ( -Arrow C- ) and tighten to the specified tightening torque. →
Tightening torque: 1.4 (1.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
Subsequent work
Subsequent work
1. Install rear centre air jet → 855719 Removing and installing rear centre air jet - section on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Installation Location:
Removing and installing pin for armrest on centre console
Note
Before unhooking the damper, secure the oddments tray and prevent it from closing.
Unclipping safety clip
3. Unhook both dampers -3- ( -Arrow C- ).
Unhooking dampers
4. Unclip safety clip -2- on pin -Arrow D- .
Installation Location:
Hooking in dampers
5. Close oddments tray
-Arrow A- .
Subsequent work
Subsequent work
1. Install rear cover for centre console → 681737 Removing and installing rear cover for centre console -
section on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Installation Location:
Removing and installing cover for oddments tray light
3. Unclip cover.
3.1. Insert a screwdriver at the clip connections -2- and lever out the cover -Arrow C- .
4. Remove cover.
4.1. Remove cover -Arrow D- and release electric plug connection -3- ( -Arrow E- ).
Unclipping cover Opening oddments tray
Installing cover for
oddments tray light
Removing cover
Installing cover for oddments tray light
Installation Location:
Removing and installing cover for oddments tray light
1. Position cover.
Positioning cover
1.2. Insert the tabs of the cover into the cut-outs in the trim panel -Arrows F- .
2. Engage clips.
Engaging clips Inserting tabs
2.1. Use a pointed-nose pliers to grip the locking tab and trim panel and press the locking tab into the clip -2- (
-Arrow C- ).
Subsequent work
1. Install rear cover for centre console → 681737 Removing and installing rear cover for centre console -
section on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Installation Location:
Removing and installing armrest for centre console
1. Remove armrest.
Removing armrest
1.1. Tilt the pivot axis of the armrest -1- in the opposite direction to the
pivot axis of the mount -2- ( -Arrow A- ).
Installation Location:
Subsequent work
Subsequent work
1. Install pin for armrest on centre console → 681737 Removing and installing pin for armrest on centre
console - section on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Installation Location:
Removing and installing switch for oddments tray light
2.2. Press the button -5- from inside -Arrow E- and disengage the switch fully -Arrow F- .
Installation Location:
Removing and installing switch for oddments tray light
2.2. While keeping the button pressed, move the switch until the button -5- pops out through the trim panel
-Arrow E- .
Engage switch -1- at the centre console using the locking tabs.
Subsequent work
Subsequent work
1. Install damper for armrest on centre console → 681737 Removing and installing damper for armrest on
centre console - section on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
68 19 19 Removing and installing cover for centre console - as of
MY 2003
- Removing cover for centre console
- Installing cover for centre console
Installation Location:
1. Vehicles with manual transmission: remove shift lever knob → Removing shift lever knob.
3.1. Carefully fold up cover for centre console -1- until the retaining lugs -A- can be pulled out from the guides.
3.2. Pull cover for centre console -1- by the retaining lugs -A- from the
guides.
3.2. Screw in fastening screws -3- and tighten to the specified torque. → Tightening torque: 1.5 ftlb. +0.5 ftlb.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
68 20 19 Removing and installing front ashtray - as of MY 2003
- Removing front ashtray
- Installing front ashtray
Installation Location:
1. Remove front air-conditioning system regulator. → 870219 Removing and installing front air-conditioning
system regulator - "Removing" section.
Installation Location:
1. Insert front ashtray -1- ( -arrow A- ).
2. Connect connector.
2.1. Push on the plug -3- until the locking tabs engage audibly -Arrow B- . When doing so, ensure that the plug
-3- is positioned correctly in the mount -4- for the front ashtray -1- .
3. Install front ashtray.
3.1. Insert front ashtray -1- into the guides -5- and push it in completely
-arrow A- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
1. Disengage adjustable part of the sun visor -1- from the mounting saddle and pivot towards roof frame (
-arrow A- ).
2.1. Unclip cover cap -2- on the mounting saddle -3- with a screwdriver and unfold ( -arrow B- ).
4.1. Pivot adjustable sun visor back into its normal position.
4.2. Carefully insert a screwdriver between roof lining and pivot bearing
-7- ( -arrow G- ) and release cover ( -arrow H- ).
6.1. Unclip sun visor -9- and carefully lower it ( -arrow I- ), until the plug -11- is accessible.
6.2. Release the locking tab -10- for the electrical plug connection ( -arrow K- ) and pull off the plug -11- (
-arrow L- ).
Installation Location:
4.1. Swivel adjustable part of the sun visor -1- towards roof frame ( -arrow D- ).
6.1. Unclip cover cap -2- on the mounting saddle -3- with a screwdriver (
-I- ) and unfold ( -arrow K- ).
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
68 27 19 Removing and installing interior rear-view mirror - as of
MY 2003
- Removing interior rear-view mirror
- Installing interior rear-view mirror
Installation Location:
1. Remove left and right cover caps.
1.1. Insert a plastic wedge between the cover caps -1- and carefully
press apart. Remove cover caps.
2. Remove rear-view mirror.
Installation Location:
1. Install rear-view mirror.
1.1. Push rear-view mirror -2- as far as the stop in -direction of arrow- onto the mirror support -3- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
68 35 19 Removing and installing front handle - as of MY 2003
- Removing front handle
- Installing front handle
Installation Location:
1. Unfold handle -1- .
Installation Location:
1. Position handle -1- .
2. Screw in and tighten fastening screws -3- . → Tightening torque: 3.5 ftlb.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
68 37 19 Removing and installing rear handle - as of MY 2003
- Removing rear handle
- Installing rear handle
Installation Location:
1. Unfold grab handle -1- .
Installation Location:
1. Position grab handle -1- .
2. Screw in fastening screws -3- and tighten to the specified torque. → Tightening torque: 3.5 ftlb.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
68 96 19 Removing and installing sun blind on door window - as
of MY 2003
- Removing sun blind and holder for sun blind on door window
- Installing sun blind and holder for sun blind on door window
Removing sun blind and holder for sun blind on door window
Removing sun blind and holder for door window sun blind
Installation Location:
1. Remove rear door trim panel. → 707319 Removing and installing rear door trim panel - chapter on
"Removing"
2. Remove cover.
Installation Location:
1. Remove cover.
1.1. Remove cover -2- from holder for door window sun blind -1- (
-Arrow A- ).
Installation Location:
2. Push on cover.
Installation Location:
1. Install door window sun blind.
2. Install cover.
2.1. Open up cover -1- ( -Arrows B- ) and insert above the door window sun blind -2- ( -Arrow C- ) by pulling
the sun blind -2- out slightly.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
WARNING
Danger of injury and material damage if airbag units are not handled correctly! Please observe the following points:
→ Before disposal, the airbag units must be rendered harmless by electrical ignition and while observing all precautionary measures, thereby preventing them being used incorrectly!
→ The driver and passenger airbag module are in two stages. Ensure that both stages have ignited.
Note
Country-specific statutory regulations and legislation based on them which go beyond these instructions must always be observed and take precedence over these instructions!
Note
Airbag units are pyrotechnical items and can pose an environmental hazard!
For this reason, non-ignited airbag units or entire vehicles must not be disposed of as normal scrap, refuse or in other final storage facilities!
If the vehicle suffered fire damage which caused one or several airbags or belt tensioners to be triggered, additional ignition with the adapter cable must be carried out in order to ensure
that only parts without pyrotechnical contents are scrapped!
In the case of airbag units which cannot be ignited or if the conditions for safe ignition are insufficient, always return the airbag units to Porsche or the respective importer in their original
packaging!
WARNING
Danger of injury and material damage if airbag units are not handled correctly! Please observe the following points:
→ Ignition and preparations may only be carried out by skilled staff, supervised by a second responsible person!
→ Other normal accident prevention regulations must also be observed!
→ Ignite airbag units only in their securely installed, original condition!
→ Carry out ignition only in suitable, free areas!
→ Use only the ignition tool intended for that purpose!
→ All loose objects must first be removed from the expansion area of the airbag!
→ Every ignition circuit for all airbag modules and belt tensioners must be ignited individually.
→ Persons possibly affected must be informed of the resulting noise beforehand!
→ Use ear protectors!
→ Maintain a safety distance by utilising the entire cable length of the ignition tool!
→ Connect power source only immediately prior to triggering!
→ Choose a place in front of the vehicle. This also applies to persons not involved!
→ Perform ignition with the doors closed and the side windows open!
→ Do not approach the vehicle until after a waiting period (approx. 3 minutes) if ignition fails!
→ Allow airbag units to cool down under observation following ignition!
→ Avoid skin contact with ignited airbag units!
Installation Location:
A- Purple marking on the connector - adapter for 1st stage of head, side, passenger's airbag units and belt tensioner
B- Marking A - adapter for 1st stage of driver's airbag unit
C- Marking B - adapter for 2nd stage of driver's airbag unit
D- Green marking on the connector - adapter for 2nd stage of passenger's airbag unit
E- Adapter for ignition device
Installation Location:
A - Detonator 92570
ATTENTION
Danger of injury and material damage if airbag units are not handled correctly!
→
→ Remove ignition key. Disconnect battery . Route or isolate ground strap so that all contact with a ground carrier (e.g. body, seat frame) is avoided. → 90 Work instructions after
disconnecting the battery
→ After the battery is disconnected, always wait for 1 minute before disconnecting the airbag plugs.
Driver's side
ATTENTION
Danger of injury!
Installation Location:
A- Purple marking on the connector - adapter for 1st stage of head, side, passenger's airbag units and belt tensioner
B- Marking A - adapter for 1st stage of driver's airbag unit
C- Marking B - adapter for 2nd stage of driver's airbag unit
D- Green marking on the connector - adapter for 2nd stage of passenger's airbag unit
E- Adapter for ignition device
1. Remove steering column trim. → 481319 Removing and installing trim for steering column - "Removing" section
2. Disconnect connector from the airbag on the steering column switch and first plug in the connector -B- - 1st stage - from the adapter cable
9257/4.
3. Connect the detonator 92570 to the 2-pin connector -E- of the adapter cable 92574.
4. Place the ignition device in front of the vehicle through the door gap.
5. After triggering, repeat the work step with the connector -C- - 2nd stage.
ATTENTION
Danger of injury!
Installation Location:
A- Purple marking on the connector - adapter for 1st stage of head, side, passenger's airbag units and belt tensioner
B- Marking A - adapter for 1st stage of driver's airbag unit
C- Marking B - adapter for 2nd stage of driver's airbag unit
D- Green marking on the connector - adapter for 2nd stage of passenger's airbag unit
E- Adapter for ignition device
1. Remove glove compartment → 681519 Removing and installing glove compartment - chapter on "removing"
2. Disconnect both connectors from the airbag unit and first plug in the connector -A- - 1st stage - from the adapter cable 92574 to the airbag unit
on the right.
Note
This is a two-stage airbag module with the right connection - 1st stage - and the left connection - 2nd stage.
3. Connect the detonator 92570 to the 2-pin connector -E- of the adapter cable 92574.
4. Place the ignition device in front of the vehicle through the door gap.
5. After triggering, repeat the work step on the left of the airbag unit with connector -D- - 2nd stage.
Inserting adapter cable
Side airbag
Note
Before disconnecting the battery, move the seat to the uppermost position.
Installation Location:
A- Purple marking on the connector - adapter for 1st stage of head, side, passenger's airbag units and belt tensioner
B- Marking A - adapter for 1st stage of driver's airbag unit
C- Marking B - adapter for 2nd stage of driver's airbag unit
D- Green marking on the connector - adapter for 2nd stage of passenger's airbag unit
E- Adapter for ignition device
1. Unplug the side-airbag connector and insert connector -A- from the adapter cable 92574.
2. Connect the detonator 92570 to the 2-pin connector -E- of the adapter cable 92574.
3. Place the ignition device in front of the vehicle through the door gap.
Installation Location:
A - Purple marking on the connector - adapter for 1st stage of head, side, passenger's airbag units and belt tensioner
1. Remove D-pillar trim panel. → 706919 Removing and installing D-
B- Marking A - adapter for 1st stage of driver's airbag unit pillar trim panel - "Removing" section
C- Marking B - adapter for 2nd stage of driver's airbag unit
D- Green marking on the connector - adapter for 2nd stage of passenger's airbag unit 2. Unplug the head-airbag
E- Adapter for ignition device connector and insert
connector -A- from the
adapter cable 92574.
3. Connect the detonator 92570 to the 2-pin connector -E- of the adapter cable 92574.
4. Place the ignition device in front of the vehicle through the door gap.
Installation Location:
A- Purple marking on the connector - adapter for 1st stage of head, side, passenger's airbag units and belt tensioner
B- Marking A - adapter for 1st stage of driver's airbag unit
C- Marking B - adapter for 2nd stage of driver's airbag unit
D- Green marking on the connector - adapter for 2nd stage of passenger's airbag unit
E- Adapter for ignition device
1. For the front belt tensioners, remove the B-pillar trim panel. → 706719 Removing and installing B-pillar trim panel - "Removing" section
2. For the rear belt tensioners, remove the C-pillar trim panel and the rear side-panel lining . → 706819 Removing and installing C-pillar trim panel - "Removing" section
→ 700319 Removing and installing rear side trim panel for luggage compartment - "Removing" section
3. Unplug the connector on the seat-belt tensioner and insert connector -A- from the adapter cable 92574.
4. Connect the detonator 92570 to the 2-pin connector -E- of the adapter cable 92574.
5. Place the ignition device in front of the vehicle through the door gap.
Ignition
ATTENTION
Danger of injury from explosion noises and flying interior parts!
The airbag components and belt tensioner and must be ignited separately!
Note
Attach the ignition device to a separate vehicle battery and press the button.
Ignition
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45,
C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
WARNING
Incorrect handling of airbag units! (Part 1)
Danger of injury and material damage as a result of exploding airbag
WARNING
Incorrect handling of airbag units! (Part 2)
Danger of injury and material damage as a result of exploding airbag!
→ Please observe the following points:
→ Airbag units must be kept in a locked place!
→ When storing airbag units, ensure that the airbag opening faces upwards (risk of injury caused by inflation of
the airbag units in the event of accidental ignition)!
→ Airbag units must be stored in a dry place and must not be stored together with other hazardous goods
(varnishes, etc.)!
→ Loose airbag units, referred to as airbag modules below, or airbag modules installed in a loose steering wheel
must never become the actual (physical) property of the customer!
→ The possession of loose airbag modules not installed in the vehicle is not permissible in the private sector!
→ Airbag modules may become the property of the customer only when installed in the vehicle!
→ Airbag modules must not be deposited on a metallic surface.
DANGER
Malfunction in airbag system
Danger of personal injury
WARNING
Danger of injury and material damage if airbag units are not handled correctly! Please observe the
following point:
→ Inspection and assembly work may only be carried out by specialist staff
Before working on the airbag system and also when working on neighbouring parts where there is a risk because
live parts are close to the airbag system, always implement the following safety measures:
WARNING
Danger of injury and material damage if airbag units are not handled correctly! (Part 1) Please observe the
following points:
→ Inspection and assembly work must only be carried out by specialist staff!
→ After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar tools must
not be started until after a waiting period of 1 minute! This is necessary in order to interrupt the power supply
to the airbag system and to ensure it is not triggered accidentally!
→ Airbag units must be fitted immediately after being removed from their storage location!
→ Airbag units must never be left lying around unattended!
→ If work is interrupted, airbag units must immediately be locked away again!
→ Airbag units must not come into contact with grease, oil, detergents, liquids, or similar substances!
→ Airbag units may not be exposed to temperatures above 90 °C!
→ Airbag units and control units which have fallen from a low height may no longer be installed!
→ No additional linings, stickers or similar may be attached to the steering wheel in the vicinity of the
passenger's airbag, side airbag, and the head airbag!
→ Changes must not be made to the wiring or the components of the airbag system!
→ The battery must always be disconnected before starting straightening and welding work with an electrical
welding unit!
→ Electrostatic charge: In general, suitable work clothing and footwear are to be worn. → 69 WM Safety
regulations for vehicles with airbag and belt tensioner - "Tools and materials" section
→ Do not remove the short-circuit spring of the plug contacts.
→ Never connect airbag units to electrical power sources not in accordance with regulations (danger of
immediate ignition). Only use testers prescribed by the manufacturer. → 690101 Airbag diagnosis.
WARNING
Danger of injury and material damage if airbag units are not handled correctly! (Part 2) Please observe the
following points:
→ The airbag triggering unit must be removed in advance if you have to perform welding in the immediate
vicinity of the airbag triggering unit!
→ Airbag components may not be repaired!
→ Airbag components must always be replaced!
→ Wash your hands after touching triggered airbag units!
Note
Injury caused by incorrect triggering of the installed unit.
Airbag/belt tensioner components should neither be opened nor repaired; always use only new parts.
Injury caused by incorrect triggering due to tampering with the short circuit bridges.
Protective measures and rules of behaviour
Note
Assembly work only by trained staff.
Carry out tests only with the Porsche System Tester diagnostic module; do not use test lamps, voltmeters or
ohmmeters.
Do not bring into contact with grease, solvents, cleaning agents, or liquids.
Keep the unfolding area of the airbag clear; e.g. do not hang test devices over the steering wheel. When
carrying, hold the airbag with the blow-out direction facing away from the body. Store the unit with the airbag
facing upwards.
Electrostatic charge: In general, suitable work clothing and footwear are to be worn. → 69 WM Safety
regulations for vehicles with airbag and belt tensioner - "Tools and materials" section
Never connect airbag units to electrical power sources not in accordance with regulations (danger of
immediate ignition). Only use testers prescribed by the manufacturer. → 690101 Airbag diagnosis.
During installation/removal or work on the vehicle involving vibrations: switch off ignition, disconnect and cover
the negative terminal of the battery, wait 1 minute and only then disconnect the plug connection.
Storage in the workshop: max. 10 kg (=> 100 driver's or 50 passenger's airbags); protect against theft!
The installation of the airbag/belt tensioner unit must be carried out immediately after removal from the
transport container.
If work is interrupted, the airbag/belt tensioner unit must be stored in the transport container again.
Note
Protect against flames and heat.
In case of fire, inform the fire brigade about the present units as it arrives.
Do not install mechanically damaged units or units that have fallen from a low height.
Because of the irritating combustion residues, only handle triggered airbags with protective gloves and
goggles.
In the case of contact with combustion residues, wash the affected skin with soap and water.
Materials
General information
The airbag system is constantly monitored by a diagnosis unit in the triggering unit. Any fault is signalled by a
warning light. The warning light for the airbag system lights up in the event of a fault. The airbag warning light lights
for approx. 3 seconds after the ignition is switched on and goes out if no fault has been entered in the fault
memory. If it lights up again, this indicates a fault in the system. The fault can be read out with the Porsche System
Tester 2.
Note
A period of 10 seconds is required to enable the triggering unit to identify all faults in the system!
In order to guarantee that every possible fault source is checked during the vehicle test, the ignition must be
switched on for at least 10 seconds!
The fault memory must be cleared following a fault in the airbag system and after it has been remedied!
The replacement of a component must be noted in the Guarantee and Maintenance booklet!
To do this, attach the documentation number in a free panel intended for that purpose!
Exchanged airbag units or airbag modules must be taken into possession by the Porsche Centre or by a
dealer authorised by Porsche and must not be handed over to the customer (customer has no right to possess
them). They must be destroyed, disposed of or returned to the manufacturer in accordance with the explosives
ordinance and the hazardous materials ordinance!
When the steering wheel is exchanged, e.g. to install a steering wheel from the Tequipment product range, the
airbag unit of the replaced steering wheel must be removed and destroyed, disposed of or returned to the
manufacturer before the steering wheel is handed over to the customer!
The following components must be removed and replaced after the airbag system is triggered:
After triggering of the belt tensioner, driver's, passenger's, and/or rear unit.
After triggering one or more airbag units (driver's, passenger's, head and/or side airbag).
Note
Because it is difficult to visually determine if one or more belt tensioners has been triggered, check the
following points.
Read out the airbag fault memory with the Porsche System Tester.
Pull out the belt strap as far as possible and check for wear.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Airbag diagnosis
1. Function test of the airbag system:
Note
When you perform the drive link test:
The cutoff relay is activated. The cutoff relay must be activated again. To activate the cutoff relay: Press on
the coloured area of cutoff relay (located in current distributor).
1.6. Read out fault memory for all control units and erase if necessary.
1.7. Remove ignition key. Disconnect battery . Route or isolate ground strap so that all contact with a ground
carrier (e.g. body, seat frame) is avoided. → 90 Work instructions after disconnecting the battery
ATTENTION
Danger of injury and material damage if airbag units are not handled
correctly!
→ Always observe the safety regulations for handling airbag units → 69
Safety regulations for vehicles with airbag and belt tensioner
→ After the battery is disconnected, always wait for 1 minute before
disconnecting the airbag plugs.
Note
Loosening seat airbag connector
To check the operation of the airbag system, a plug connection is
disconnected from an airbag unit. A fault code - Static fault - must then be stored in the Porsche System
Tester.
2.1. Simulate the fault using the side airbag, for example. Move seat all the way forward.
2.2. Push down the safety cover on the plug socket -1- -arrow A- and hold in this position.
2.3. Open locking mechanism -arrow B- on airbag connector -2- and remove connector -arrow C- .
3.1. Switch off ignition, disconnect the battery and wait for 1 minute.
3.2. Insert connectors -2- on plug socket -1- -arrow A- until connectors
are felt to engage.
4. Read out and delete faults:
Note
Fault memory shows a sporadic fault.
Inserting seat airbag connector
4.1. Connect the battery, switch ignition on and read out the fault
memory with the Porsche System Tester.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
69 11 19 Removing and installing front three-point belt - as of MY
2003
- Removing front three-point belt
- Installing front three-point belt
Installation Location:
ATTENTION
Danger of injury and damage to property as a result of incorrect handling of belt tensioner units! Always
observe the safety regulations for handling belt tensioner units. → 69 Safety regulations for vehicles with
airbag and belt tensioner
If removed for an extended period, the belt tensioner unit must be kept in a secure location!
The belt tensioner unit must be transported and stored so that the seat belt can safely retract if it
should be actuated.
Remove ignition key. Disconnect battery. Route or isolate ground strap so that all contact with a
ground carrier (e.g. body, seat frame) is avoided. → 90 Work instructions after disconnecting the
battery .
After the battery is disconnected, always wait for 1 minute before disconnecting the belt tensioner
plugs.
→
1. Remove inner sill. → 680519 Removing and installing inner sill - "Removing" section
2. Pull out seat belt cover at front -A- and remove towards the front -B- .
4. Push belt end mount over the retaining pins -arrow B- until the locking
tab relaxes the clip underneath the retaining pin.
5. Remove belt end mount from the retaining pin -arrow A- and pull seat
belt out through the belt guide -arrow B- .
7. Twist the top belt lug -arrow A- and push downwards behind the holder -arrow B- .
8. Pull out belt buckle -C- with belt end mount -D- towards the bottom.
10. Press down the protective cover on the plug -arrow A- and maintain in this position.
12. Unscrew fastening screw -2- on the belt reel. Left belt reel -arrow A- , disengage towards the back -arrow B-
and remove upwards -arrow C- .
Installing front three-point belt
ATTENTION
Safety-related bolts!
Always replace fastening screws of the three-point belt after customer service and reworking.
Never make alterations to the micro-encapsulated screws, which have a negative effect on the bond
(e.g. using lubricant, loosening bolts and screwing them down again).
Installation Location:
1. Position belt reel in the mounting opening -A- , ensuring that the
threaded bore is aligned with the thread.
2. Tighten belt reel with the fastening screw -2- . → Tightening torque: 50 (37 ftlb.) Nm
Note
Do not twist the three-point belt when installing!
3. Push through belt end mount -A- and belt buckle -B- upwards behind
the holder.
4. Turn belt lug -arrow C- and push it upwards behind the holder
-arrow D- .
Note
Once the fastening screw has been tightened, the belt lug must level out on its own in a vertical position or in
the relevant support direction.
5. Fasten belt lug on the vertical adjustment device with the fastening screw -1- . → Tightening torque: 37 ftlb.
Note
When routing the electric wires, ensure that they are not routed
through the belt-coiling area.
7. Push socket onto the clip -arrow A- until it clicks into place -arrow B- .
8. Push seat belt through the belt guide on the seat -arrow A- .
9. Position belt end fitting on the retaining pin -arrow B- and pull upward -arrow C- until the retaining clip locks
with an audible click.
10. Engage seat belt cover at seat trim -arrow A- and push in -arrow B-
until it can be felt to engage.
11. Install inner sill. → 680519 Removing and installing inner sill -
"Installing" section
The belt strap must be fully rolled up when the function test is started.
Move the seat belt height adjustment to the highest position.
Pull out belt strap completely as far as it will go.
Roll up the belt strap again slowly. An audible clattering noise can be heard when you do this.
If the rolling-up process is interrupted, the belt strap cannot be pulled out again (permanent belt blockage).
The permanent belt blockage feature must be disabled at least 100 mm before the belt strap is completely
rolled up in order to ensure that the belt strap can be pulled out again.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
69 12 19 Removing and installing rear three-point belt - as of MY
2003
- Removing rear three-point belt
- Installing rear three-point belt
Installation Location:
ATTENTION
Danger of injury and material damage if belt tensioner units are not handled correctly! Always observe
the safety regulations for handling belt tensioner units. → Safety regulations for handling airbag and...
If removed for an extended period, the belt tensioner unit must be kept in a secure location!
The belt tensioner unit must be transported and stored so that the seat belt can safely retract if it
should be actuated.
Remove ignition key. Disconnect battery. Route or isolate ground strap so that all contact with a
ground carrier (e.g. body, seat frame) is avoided. → Work instructions after disconnecting the
battery
After the battery is disconnected, always wait one minute before disconnecting the belt tensioner
connectors.
→
1. Fold seat cushion forwards.
6. Unscrew fastening screws -2- and remove the support from the
backrest.
7. Press down the protective cover on the plug -Arrow A- and maintain
in this position.
Installation Location:
1. Remove backrest. → 724719 Removing and installing rear backrest - "Removing" section
3. Remove padding for rear backrest. → 745219 Removing and installing padding for rear backrest -
"Removing" section
4. Unscrew fastening screw -5- and remove the belt reel downwards.
5. Turn seat-belt buckle -arrow A- and push it into the belt guide -arrow B- .
Installation Location:
ATTENTION
Safety-related bolts!
Always replace fastening screws of the three-point belt after customer service and reworking.
Never make alterations to the micro-encapsulated screws, which have a negative effect on the bond
(e.g. using lubricant, loosening bolts and screwing them down again).
1. Insert belt reel -arrow- and tighten with the fastening screw -3- . → Tightening torque: 37 ftlb.
Note
During installation make sure that the belt strap runs in front of the
belt deflector -arrows- .
Once the fastening screw has been tightened, the deflection lug must
level out on its own in a vertical position or in the relevant support
direction.
3. Push socket onto the clip -Arrow A- until it clicks into place -Arrow B- .
Note
When routing the electric wires, ensure that they are not routed
through the belt-coiling area.
6. Fasten support for the backrest with the fastening screws -2- . →
Tightening torque: 20 (15 ftlb.) Nm
Note
The belt strap for the three-point belt must be routed over the side
cushions and must not be trapped.
The belt end mount must not come into contact with the side trim panel.
9. Pull three-point belt downward -arrow- , align belt anchor fitting in middle of structure seam and fasten with
fastening screw -1- . → Tightening torque: 37 ftlb.
10. Carry out work instruction after disconnecting the battery. → Work instructions after disconnecting the
battery
The belt strap must be fully rolled up when the function test is started.
Move the seat belt height adjustment to the highest position.
Pull out belt strap completely as far as it will go.
Roll up the belt strap again slowly. An audible clattering noise can be heard when you do this.
If the rolling-up process is interrupted, the belt strap cannot be pulled out again (permanent belt blockage).
The permanent belt blockage feature must be disabled at least 100 mm before the belt strap is completely
rolled up in order to ensure that the belt strap can be pulled out again.
Installation Location:
ATTENTION
Safety-related bolts!
Always replace fastening screws of the three-point belt after customer service and reworking.
Never make alterations to the micro-encapsulated screws, which have a negative effect on the bond
(e.g. using lubricant, loosening bolts and screwing them down again).
2. Twist seat-belt buckle -arrow B- and pull it out of the belt guide -arrow C- .
3. Position belt reel between the two guide lugs -arrow- and screw down with the fastening screw -5- . →
Tightening torque: 37 ftlb.
4. Install padding for rear backrest. → 745219 Removing and installing padding for 2/3-split folding backrest -
"Installing" section
6. Install backrest. → 724719 Removing and installing rear backrest - "Installing" section
7. Perform a function test.
The belt strap must be fully rolled up when the function test is started.
Move the seat belt height adjustment to the highest position.
Pull out belt strap completely as far as it will go.
Roll up the belt strap again slowly. An audible clattering noise can be heard when you do this.
If the rolling-up process is interrupted, the belt strap cannot be pulled out again (permanent belt blockage).
The permanent belt blockage feature must be disabled at least 100 mm before the belt strap is completely
rolled up in order to ensure that the belt strap can be pulled out again.
The belt strap must be able to run freely in all directions.
Installation Location:
1. Move front and rear of seat to highest position.
ATTENTION
Remove ignition key. Disconnect battery. Route or isolate ground strap so that all contact with a ground
carrier (e.g. body, seat frame) is avoided. → Work instructions after disconnecting battery
2. Remove front seat. → 720119 Removing and installing front seat - chapter on "removing"
3. Press together the locking tabs of the clip -Arrows A- and pull out the plug, together with the clip, in a
downward direction -Arrow B- .
4. Press the locking tab to the side -arrow C- and remove the plug from the clip -arrow D- .
6. Separate the two tie-wraps -B- and unscrew the fastening screw -1- .
ATTENTION
Safety-related bolts!
Always replace fastening screws of the belt buckle after customer service and reworking.
Never make alterations to the micro-encapsulated screws, which have a negative effect on the bond
(e.g. using lubricant, loosening bolts and screwing them down again).
→
Once fitted, the seat-belt buckle must be able to turn smoothly around
the fastening point.
Installation Location:
1. Install belt buckle and tighten with the fastening screw -1- . → Tightening torque: 50 (37 ftlb.) Nm
2. Attach the cable with tie-wraps -A- to the two clips and engage in the bracket on the inner spring -arrow B- .
4. Plug the connector together with clip onto the retaining frame -arrow B- until the clip perceptibly locks into
the retaining frame.
5. Install front seat. → 720119 Removing and installing front seat - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
69 25 19 Removing and installing rear belt lock - as of MY 2003
- Removing rear belt lock
- Installing rear belt lock
Installation Location:
1. Lift front edge of right back seat -arrow A- , pull out to the front
-arrow B- , and fold forward -arrow C- .
Installation Location:
1. Position belt buckle. Screw in and tighten the front fastening nut -1- . → Tightening torque: 37 ftlb.
3. Screw in and tighten the rear fastening nut -2- . → Tightening torque: 50 (37 ftlb.) Nm
4. Fold back back seat -arrow A- , press downward at the front edge -arrow B- and push to the rear -arrow C-
.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38,
C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
WARNING
The support plate with threaded parts will be damaged in the event of impact with seat belt buckled.
Damage to the support plate can lead to impairment in functional capability of the restraint system
and personal injury as a consequence.
When replacing the safety belt following accident damage, the support plate of the adjustment fitting
and the threaded parts must also be replaced for safety reasons.
Installation Location:
1. Remove C-pillar trim. → 706819 Removing and installing C-pillar trim - chapter on "removing"
Note
For safety reasons, the fastening screw -1- for the adjustment fitting
support plate must be replaced after removal.
1. Insert rear support plate. Ensure that the tabs -A- lie inside the
spacer sleeves.
2. Screw in the fastening screw -1- so that the top of the support plate
can still just be moved.
Note
For safety reasons, the fastening screw -1- for the adjustment fitting
must be replaced after removal.
Installation Location:
1. Engage the adjustment fitting on the support plate at the bottom -Arrow A- and fold inwards at the top
-Arrow B- .
2. Screw down support plate and adjustment fitting with the fastening screws -1- top and bottom. → Tightening
torque: 4.5 (3.5 ftlb.) Nm
3. Install C-pillar trim. → 706819 Removing and installing C-pillar trim - chapter on "installing"
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove B-pillar trim. → 706719 Removing and installing B-pillar trim - "Removing" section
2. Remove inner sill. → 680519 Removing and installing inner sill - "Removing" section
ATTENTION
Risk of material damage to support plate with threaded parts in the event of impact with seat belt buckled!
Installation Location:
Overview of electric adjustment fitting
1. Unscrew the fastening screws -arrows 1- and remove the holder -arrow A- .
2. Unscrew the fastening nut -arrow 2- and remove the deflection lug -arrow B- .
3. Undo fastening nuts -arrows 3- and remove holder with the plug connections -arrow- .
4. Release plug connection -arrow A- and remove it from the clip -arrow B- .
7. Unscrew fastening screw -arrow 5- and pull the adjustment fitting upwards -arrow- .
Removing holder and deflection lug Removing holder and deflection lug
Removing support
Note
Grease the spindle with acid-free grease before assembling the adjustment fitting.
2. Insert the shaft into the adjustment fitting -arrow B- until you feel the locking tabs -arrows C- engage. Turn
the spindle -a- slightly, if necessary.
Note
The fastening screws for the support plate -arrow 5- and adjustment fitting must be replaced following
removal for safety reasons.
Adjusting motor and shaft Adjusting motor and shaft
3. Engage the adjustment fitting
at the bottom -arrow- and
tighten at the top with the
fastening screw -arrow 5- .
→ Tightening torque: 3.0
ftlb.
Fastening screws for support plate and Fastening screws for support plate and
adjustment fitting adjustment fitting
4. Screw the adjusting motor on securely using the fastening screws -arrows 4- . → Tightening torque: 1.5
(1.0 ftlb.) Nm
5. Push plug connection together -arrows A- until the locking lug -arrow B- is felt to engage.
6. Push the plug connection onto the clip -arrow C- until you feel the locking hook -arrow D- engage.
7. Position the support in installation position -arrow- and secure with the fastening nuts -arrows 3- . →
Tightening torque: 6.0 ftlb.
Note
Once the fastening nut has been tightened, the deflection lug must level out on its own in a vertical position
or in the relevant support direction.
Connecting plug connections Fastening screws for support plate and
adjustment fitting
Note
Once the fastening nut has been tightened, the deflection lug must
level out on its own in a vertical position or in the relevant support
direction.
8. Tighten the deflection lug on the adjustment fitting with the fastening
nut -arrow 2- . → Tightening torque: 37 ftlb.
Subsequent work
Subsequent work
1. Install inner sill. → 680519 Removing and installing inner sill - "Installing" section
2. Install B-pillar trim. → 706719 Removing and installing B-pillar trim - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
→ 69 Safety regulations for vehicles with airbag and belt tensioner
Preliminary work
Removing front apron. → 631519 Removing and installing front apron - "Removing" chapter
Remove front seat. → 720119 Removing and installing front seat - "Removing" section
Remove rear side trim panel. → 700319 Removing and installing side trim panel for rear luggage compartment -
"Removing" section.
The middle two sensors are located on the floorpan behind the front seats.
The rear two sensors are located on the rear wheel housings.
Installation Location:
→ Always observe the safety regulations for handling airbag units → 69
Safety regulations for vehicles with airbag and belt tensioner
→ Remove ignition key. Disconnect battery. Route or isolate ground
strap so that all contact with a ground carrier (e.g. body, seat frame)
is avoided. → 90 Work instructions after disconnecting the battery Disconnecting sensor
→ Before the connector is disconnected from the sensor, always wait
for 1 minute before disconnecting the battery.
1. Push in lock -2- on plug for sensor -1- , until this perceptibly engages -arrow A- .
2. Release locking mechanism on the latch -2- -arrow B- and pull off
plug from sensor -1- -arrow C- .
Disconnecting sensor
3. Unscrew the two fastening nuts -3- and remove the sensor.
Removing sensor
Removing middle sensor
Note
Accessibility is limited. If the carpet is pulled back too far, it will tear at the edges.
→ Always observe the safety regulations for handling airbag units → 69
Safety regulations for vehicles with airbag and belt tensioner
→ Remove ignition key. Disconnect battery. Route or isolate ground
strap so that all contact with a ground carrier (e.g. body, seat frame)
is avoided. → 90 Work instructions after disconnecting the battery
→ Before the connector is disconnected from the sensor, always wait Disconnecting sensor
for 1 minute before disconnecting the battery.
2. Push in lock -2- on plug for sensor -1- , until this perceptibly engages -arrow A- .
3. Release locking mechanism on the latch -2- -arrow B- and pull off
plug from sensor -1- -arrow C- .
Disconnecting sensor
4. Unscrew the two fastening screws -4- and remove the sensor.
Removing sensor
Removing sensor on wheel housing
ATTENTION
Danger of injury and damage to property as a result of incorrect handling of airbag sensors!
Risk of confusing the front, middle and rear sensors, since they do not differ in appearance.
Disconnecting sensor
→ Always observe the safety regulations for handling airbag units → 69 Safety regulations for vehicles with
airbag and belt tensioner
→ Remove ignition key. Disconnect battery. Route or isolate ground strap so that all contact with a ground
carrier (e.g. body, seat frame) is avoided. → 90 Work instructions after disconnecting the battery
→ Before the connector is disconnected from the sensor, always wait for 1 minute before disconnecting the
battery.
1. Push in lock -2- on plug for sensor -1- , until this perceptibly engages -arrow A- .
2. Release locking mechanism on the latch -2- -arrow B- and pull off
plug from sensor -1- -arrow C- .
Disconnecting sensor
3. Unscrew the two fastening screws -4- and remove the sensor.
Removing sensor
→ Always replace fastening screws of the sensors after customer service and reworking.
→ Never make alterations to the micro-encapsulated screws, which have a negative effect on the bond (e.g.
using lubricant, loosening bolts and screwing them down again).
Note
6 sensors are used for the airbags in the Cayenne.
The middle two sensors are located on the floorpan behind the front seats.
The rear two sensors are located on the rear wheel housings.
Note
Make sure that the sensor is properly positioned.
WARNING
Danger of injury caused by loose, safety-related bolts!
→ Always replace fastening screws of the sensors after customer
service and reworking.
→ Never make alterations to the micro-encapsulated screws, which
have a negative effect on the bond (e.g. using lubricant, loosening
bolts and screwing them down again).
Inserting sensor
Note
Make sure that the sensor is properly positioned.
1. Position sensor and screw onto the floorpan with the two fastening
screws -4- . → Tightening torque: 6.5 ftlb.
WARNING
Danger of injury caused by loose, safety-related bolts!
→ Always replace fastening screws of the sensors after customer service and reworking.
→ Never make alterations to the micro-encapsulated screws, which have a negative effect on the bond (e.g.
using lubricant, loosening bolts and screwing them down again).
Note
Make sure that the sensor is properly positioned.
1. Position sensor and screw onto the wheel arch with the two fastening
screws -4- . → Tightening torque: 6.5 ftlb.
2. Slide the connector onto the sensor until it clicks into place.
Inserting sensor
Subsequent work
3. Read out the airbag fault memory with the Porsche System Tester.
3. Read out the airbag fault memory with the Porsche System Tester.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
69 53 19 Removing and installing triggering unit for airbag - as of
MY 2003
- Removing triggering unit for airbag
- Installing triggering unit for airbag
- Locking triggering unit
Installation Location:
Overview of airbag triggering unit
ATTENTION
Incorrect handling of airbag units!
Danger of injury and material damage!
→ Always observe the safety regulations for handling airbag units → 69
Safety regulations for vehicles with airbag and belt tensioner.
→ Remove ignition key. Disconnect battery. Route or isolate ground
strap so that all contact with a ground carrier (e.g. body, seat frame)
is avoided. → 90 Work instructions after disconnecting the battery
→ Before the connector is disconnected from the triggering unit, always Opening shelf and removing cover
wait for 1 minute before disconnecting the battery. The airbag
triggering unit must not be removed with the plug plugged in!
1. -arrow A- Fold up shelf.
Removing plug
5. -arrow C- Push in plug lock -arrow 1- , fold lever -arrow 2- over and
pull off plug.
3. Insert plug connection for the lock until the plug engages.
Note
The power supply for the Porsche System Tester must be guaranteed during the locking process. Connect a
battery charging device to the vehicle battery.
The Porsche System Tester instructions take precedence and in the event of a discrepancy these are the
instructions that must be followed. A discrepancy may arise with later software versions (from 15,0).
The procedure described here has been structured generally, 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 the ignition. Press
>> to continue.
2. Select vehicle type using the cursor keys. Press >> to continue.
3. Select Airbag with the cursor keys and press the >> key.
4. In the Airbag menu, select Lock with the cursor keys and press the >> key.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove driver's airbag unit. → 695819 Removing and installing driver's airbag unit - "Removing" section
2. Remove steering wheel. → 481019 Removing and installing steering wheel - "Removing" section
3. Remove steering column trim. → 481319 Removing and installing steering column trim - "Removing" section
4. Remove and disassemble steering column switch. → 945019 Removing and installing steering column
switch - "Removing" section
ATTENTION
Incorrect handling of airbag units!
Danger of injury and material damage!
→ Always observe the safety regulations for handling airbag units → 69 Safety regulations for vehicles with
airbag and belt tensioner
Note
Ensure that arrow -arrow A- of the rotor is positioned between the
markings -arrow B- of the arrows -arrow C- of the airbag contact unit
and that the locking element -arrow D- is engaged.
1. Carefully lift up the three retaining tabs and remove airbag contact unit.
Lifting retaining lugs and removing
contact unit
ATTENTION
Risk of damaging airbag contact unit!
If the contact unit has been adjusted, proceed in accordance with the following work instruction:
→ To position the airbag contact unit in the central position, press the locking element and turn the rotor
carefully to the left as far as it will go.
→ Then turn the rotor carefully to the right, approx. 3.5 to 3.75 revolutions, until the band printed on one side is
visible in the window.
1. Position airbag contact unit and press onto the steering column
switch until the three tabs engage.
Note
The steering-angle sensor must be re-calibrated after replacing the airbag contact unit.
To correctly calibrate the steering angle sensor, the vehicle must be on the measuring platform.
The steering angle sensor must be calibrated using the menu with Porsche System Tester under the specified
test conditions:
In the straight-ahead position, the steering wheel may be turned by max. ±2.0° from the horizontal position
(steering centre position).
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Continue
with >> key.
3. Select the PSM control unit and activate using the >> key.
4. Select Actual values and activate with the >> key.
6. Note the security code and use the << key to go back to the calibration.
10. Select Steering-angle sensor and activate with the >> key.
12. After successful calibration, the stored fault code is erased from the fault memory. The PSM indicator light in
the instrument cluster goes out.
13. Read out the fault memory and, if necessary, erase it.
Subsequent work
Subsequent work
1. Assemble and install steering column switch → 945019 Removing and installing steering column switch -
"Installing" section
2. Install steering column trim. → 481319 Removing and installing steering column trim - "Installing" section
3. Install steering wheel. → 481019 Removing and installing steering wheel - "Installing" section
4. Install driver's airbag unit. → 695819 Removing and installing driver's airbag unit - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Remove trim under dashboard at passenger's side. → 701919 Removing and installing trim under instrument
panel - "Removing section"
Installation Location:
Overview of airbag switch
1. Push in the retainer springs on the switch -arrows A- and pull switch out from the mounting point.
Note
Switch off the ignition.
Removing switch
1. Insert the switch in the mounting point until the retainer springs click
into place.
Installing switch
Subsequent work
Subsequent work
Remove trim under dashboard at passenger's side. → 701919 Removing and installing trim under instrument
panel - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
WARNING
Danger of injury and material damage if airbag units are not handled correctly!
Installation Location:
Overview of driver's airbag unit
1. Switch on the ignition and move the steering wheel back and down as far as possible.
4. Insert a long hexagon-socket wrench (size 3 with ball head) fully into the opening on the back of the steering
wheel -arrow C- , press the strap outwards -arrow D- and pull the airbag unit.
5. Turn the steering wheel 180° -arrow B- , position the long hexagon-socket wrench through the opening in
the steering wheel and press the strap out -arrow D- .
6. Pull airbag unit down from the steering wheel, turn steering wheel back 180° if necessary -arrow A- and
repeat process.
Undoing airbag unit Undoing airbag unit
7. Disconnect electrical plug connection on the steering column switch and remove airbag unit.
Note
The airbag unit is fastened with a strap to the steering wheel. The
strap can be pressed apart at the two openings using a screwdriver.
Note
To make sure that the emission spring on the airbag unit is not positioned on the foam section of the steering
wheel, the airbag unit must not be tilted from top to bottom on the steering wheel.
Two additional electrical connectors need to be connected to the steering column support for heated steering
wheels.
ATTENTION
Danger of injury and material damage!
→ Before installing the airbag unit, check to see whether the leg spring and/or the metal stop are bent.
→ The airbag unit must only be installed using operational leg springs in the correct position.
→ The leg spring must not jam or grind.
→ Maintain a maximum distance whilst checking the equipment.
→ Do not expose face and other parts of the body to the airbag unit.
2. Visual inspection : The leg spring and metal stop must not be bent.
1 - Spring
2 - Metal stop
ATTENTION
Risk of damage!
→ Make sure that the electrical buttons on the airbag unit are not
damaged.
ATTENTION
Risk of damage!
Engaging the airbag unit Installing airbag unit
→ Make sure that the electrical buttons on the airbag unit are not damaged.
6. Insert the airbag unit into the steering wheel with both hands using intermittent pressure.
Note
It is important to ensure that the strap on the airbag unit is completely
engaged. This can be ensured by pulling and pressing on the airbag
unit.
Subsequent work
Subsequent work
Connect the battery and carry out work instructions after disconnecting the battery. → 90 Work instructions after
disconnecting the battery
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Disconnect battery. → 90 Work instructions after disconnecting the battery
2. Remove cover under dashboard on the passenger's side. → 702219 Removing and installing cover under
dashboard - "Removing" section
3. Remove glove compartment. → 681519 Removing and installing glove compartment - "Removing" section.
WARNING
Danger of injury and material damage if airbag units are not handled correctly!
→ Always observe the safety regulations for handling airbag units → 69 Safety regulations for vehicles with
airbag and belt tensioner
→ The airbag unit must always be stowed so that the airbag opening faces upwards!
→ If removed for an extended period, the airbag unit must be kept in a locked place!
→ Switch off ignition and leave ignition key inserted (steering must not be locked). Disconnect battery. Route or
isolate ground strap so that all contact with a ground carrier (e.g. body, seat frame) is avoided. → 90 Work
instructions after disconnecting the battery .
→ After the battery is disconnected, always wait for 1 minute before disconnecting the airbag plugs.
Installation Location:
1. Press down the protective covers on the right and left plug -arrow A-
and maintain in this position.
WARNING
Danger of injury caused by loose, safety-related bolts!
→ Always replace fastening screws of the after customer service and reworking.
→ Never make alterations to the micro-encapsulated screws, which have a negative effect on the bond (e.g.
using lubricant, loosening bolts and screwing them down again).
2. First tighten the fastening screws -arrows B- on the dashboard, then the fastening screws -arrows A- on the
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Note
Before removing, make sure that the front seat is adjusted to the highest position.
1. Remove front seat. → 720119 Removing and installing front seat - "Removing" section
2. Remove front backrest frame. → 721919 Removing and installing front backrest frame - "Removing" section
WARNING
Danger of injury and material damage if airbag units are not handled correctly!
→ Always observe the safety regulations for handling airbag units → 69 Safety regulations for vehicles with
airbag and belt tensioner
→ The airbag unit must always be stowed so that the airbag opening faces upwards!
→ If removed for an extended period, the airbag unit must be kept in a locked place!
→ After the battery is disconnected, always wait for 1 minute before disconnecting the airbag plugs.
Installation Location:
1. Push the inner edge of the protective cover for the wiring harness inwards -arrow A- and pull out the
protective cover in a downward direction -arrow B- .
3. Lift wiring harness for side airbag up and out -arrow D- . Make sure that the two plugs are not damaged.
5. Fold backrest cushion underneath the side airbag forwards -arrow B- and use a screwdriver -arrow C- to
ensure that it does not fold back.
Removing protective cover Removing protective cover
5. Guide side airbag wiring harness through the backrest frame. Make
sure that the two plugs are not damaged when you do this.
Note
Ensure that the tie-wrap is installed correctly as it can impact on the
backrest frame and hinder installation of the protective cover.
Subsequent work
Subsequent work
1. Install front backrest frame. → 721919 Removing and installing front backrest frame - "Installing" section
2. Install front seat. → 720119 Removing and installing front seat - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Disconnect battery. → 90 Work instructions after disconnecting the battery
2. Remove A-pillar trim. → 705719 Removing and installing A-pillar trim - "Removing" section
3. Remove the B-pillar trim. → 706719 Removing and installing B-pillar trim - "Removing" section
4. Remove C-pillar trim. → 706819 Removing and installing C-pillar trim - "Removing" section
5. Remove D-pillar trim. → 706919 Removing and installing D-pillar trim - "Removing" section
6. Remove rear roof trim panel. → 708419 Removing and installing roof trim panel - "Removing" section
WARNING
Danger of injury and material damage if airbag units are not handled correctly!
→ Always observe the safety regulations for handling airbag units → 69 Safety regulations for vehicles with
airbag and belt tensioner
→ If removed for an extended period, the airbag unit must be kept in a locked place!
→ Remove ignition key. Disconnect battery. Route or isolate ground strap so that all contact with a ground
carrier (e.g. body, seat frame) is avoided. → 90 Work instructions after disconnecting the battery .
→ After the battery is disconnected, always wait for 1 minute before disconnecting the airbag plugs.
Installation Location:
2. Press down the lock on the plug socket -arrow B- and maintain in this position.
4. Unscrew the three fastening screws -1- and remove the deformation element.
Note
The fastening clips must not be damaged when removing the head airbag units.
Disconnecting plug connection Disconnecting plug connection
7. Unscrew the three middle fastening screws -2- from the body in the following order: -i to k- . Hold the head
airbag unit and carefully pull out the fastening clips from the body with a screwdriver.
8. Remove the head airbag unit below the deformation element -3- and take it out.
WARNING
Danger of injury caused by loose, safety-related bolts!
→ Always replace fastening screws of the after customer service and reworking.
→ Never make alterations to the micro-encapsulated screws, which have a negative effect on the bond (e.g.
using lubricant, loosening bolts and screwing them down again).
1. Clip in the head airbag unit in the area of the middle fastening screws -2- in the order -a to c- and then
tighten the fastening screws -2- in the order -a to c- . → Tightening torque: 2.5 ftlb.
Note
The head airbag unit must be pushed -3- completely unter the deformation element -3- in the area of the
deformation element.
2. Clip in the head airbag unit in the area of the front fastening screws -2- in the order -d to g- and then tighten
the fastening screws -2- in the order -d to g- . → Tightening torque: 3.5 (2.5 ftlb.) Nm
3. Clip in the head airbag unit in the area of the rear fastening screws -2- in the order -h to k- and then tighten
the fastening screws -2- in the order -h to k- . → Tightening torque: 3.5 (2.5 ftlb.) Nm
Installing head airbag unit Installing head airbag unit
Note
Make sure that the head airbag unit is not pinched.
4. Position the deformation element and tighten with the fastening nuts
-1- . → Tightening torque: 2.5 ftlb.
Subsequent work
1. Install rear roof trim panel. → 708419 Removing and installing roof trim panel - "Installing" section
2. Install D-pillar trim. → 706919 Removing and installing D-pillar trim - "Installing" section
3. Install C-pillar trim. → 706819 Removing and installing C-pillar trim - "Installing" section
4. Install B-pillar trim. → 706719 Removing and installing B-pillar trim - "Installing" section
5. Install A-pillar trim. → 705719 Removing and installing A-pillar trim - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
Installation position
2. Unscrew the three fastening nuts -1- on the cover of the AWS control unit and remove the cover -2- .
3. Remove AWS control unit from support, release the two electric connectors -a- and pull them off the control
unit.
Remove support for the AWS control unit by pulling it upwards if necessary (e.g. if the telephone, Tiptronic,
transfer box control unit has to be removed).
Unplugging electric connectors Removing the cover
Installing AWS control unit
2. Connect the two electric connectors to the control unit until they are
felt to engage.
Subsequent work
Note
The PIWIS tester 9718 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
PIWIS tester 9718.
1. Replace control unit. → 696819 Removing and installing AWS control unit - section on "Installing"
WARNING
Sudden voltage interruption of the power supply to the control module.
Destruction of the control module.
→ During 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.
→ Prior to disconnecting the control module, switch off the ignition and remove the ignition key.
2. Connect battery charger to the vehicle. Move passenger’s seat longitudinally until flush with the seat rails
and to its lowest position.
3. Connect the Porsche System Tester PIWIS Tester 9718 to the vehicle and start the System Tester. Switch
on ignition. Press >> to continue.
5. Switch from the vehicle type to the list of control units by pressing >> .
6. Select AWS with the cursor keys and press the >> key.
7. Select Control unit replacement with the cursor keys and press the >> key.
8. The Tester displays several messages and instructions relating to the individual work steps until the
message Control unit replacement was completed successfully appears. Press >> .
9. Select the Fault memory menu in the AWS control unit. If faults are present, erase the fault memory.
10. Exit the AWS control unit and switch to the Airbag control unit.
12. Switch off the ignition when the Tester displays the prompt Switch off ignition.
13. Switch on the ignition when the Tester displays the prompt Switch on ignition.
14. When the Tester displays the message AWS was taught successfully, press >> .
15. Exit the Airbag control unit and switch to the AWS control unit.
Note
A system test can only be performed successfully if:
The AWS control unit has been taught on the airbag control unit.
16. Select the System test menu in the AWS control unit.
17. Follow the instructions on the Tester. Press >> and perform the test using the default sequence.
17.1. Seat empty - the passenger’s seat must be empty. The Passenger Airbag Off indicator light in the centre
console must not come on. To determine the status, press F7 or F8 . Then press >> .
17.2. Child - place the special tool test weight P 9742 on the passenger’s seat. The Passenger Airbag Off
indicator light in the centre console must come on. To determine the status, press F7 or F8 . Then press
>> .
17.3. Adult - get an assistant, for example, to sit on the passenger’s seat. The Passenger Airbag Off indicator
light in the centre console must not come on. To determine the status, press F7 or F8 . Then press >> .
17.4. Seat jammed - the passenger’s seat must be empty. The seat must also be relieved of any pressure, e.g.
by lifting the seat up with your hand. The Passenger Airbag Off indicator light in the centre console must
come on. In addition to the Airbag Off indicator light, a message is displayed in the instrument cluster:
Check passenger seat adjustment. To determine the status, press F7 or F8 . Then press >> .
18. To check the system, select the Actual values menu under the AWS control unit. Then press >> .
18.1. Select the Weight group (0-4) and Gross weight calibrated options.
18.1.1. If there is no weight on the passenger’s seat, compare values (see table below) using the PIWIS Tester.
The Passenger Airbag Off indicator light in the centre console must not come on.
18.1.2. Place the special tool test weight P 9742 on the passenger’s seat. The Passenger Airbag Off indicator
light in the centre console must come on. Compare values (see table below) using the PIWIS Tester.
18.1.3. Get an assistant with a body weight of more than 55 kg, for example, to sit on the passenger’s seat. The
Passenger Airbag Off indicator light in the centre console must not come on. Compare values (see table
below) using the PIWIS Tester.
19. Read out and erase the fault memories in the Airbag and AWS control unit, perform a test drive and then
read out the fault memories again. If faults are found, determine the cause using the PIWIS Tester and
correct the faults.
as of MY 2006
Country C02, C34, C36
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Later versions of the software may display slightly different text or require a slightly different procedure. The
instructions you receive from the tester itself take precedence over this description.
Note
Calibration applies to vehicles as of MY '06 with country equipment (USA, Canada, Mexico).
DANGER
Incorrect information for AWS control module.
Passenger's airbag is triggered differently.
→ If the passenger's seat was removed and re-installed, the AWS control module must be calibrated.
→ If the seat bracket was replaced, the AWS control module must be calibrated.
→ If the AWS control module was replaced, the AWS control module must be calibrated.
WARNING
Sudden voltage interruption of the power supply to the control module.
Destruction of the control module.
→ During 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.
→ Prior to disconnecting the control module, switch off the ignition and remove the ignition key.
1. Connect battery charger to the vehicle. Move passenger’s seat longitudinally until flush with the seat rails
and to its lowest position.
2. Connect the Porsche System Tester PIWIS Tester 9718 to the vehicle and start the System Tester. Switch
on ignition. Press >> to continue.
4. Switch from the vehicle type to the list of control units by pressing >> .
7. The Tester displays several messages and instructions relating to the individual work steps until the
message Test step was completed successfully appears. Press >> .
Note
A system test can only be performed successfully if:
The AWS control unit has been taught on the airbag control unit.
There are no faults in the AWS and airbag control unit.
9. Follow the instructions on the Tester. Press >> and perform the test using the default sequence.
9.1. Seat empty - the passenger’s seat must be empty. The Passenger Airbag Off indicator light in the centre
console must not come on. To determine the status, press F7 or F8 . Then press >> .
9.2. Child - place the special tool test weight P 9742 on the passenger’s seat. The Passenger Airbag Off
indicator light in the centre console must come on. To determine the status, press F7 or F8 . Then press
>> .
9.3. Adult - get an assistant, for example, to sit on the passenger’s seat. The Passenger Airbag Off indicator
light in the centre console must not come on. To determine the status, press F7 or F8 . Then press >> .
9.4. Seat jammed - the passenger’s seat must be empty. The seat must also be relieved of any pressure, e.g.
by lifting the seat up with your hand. The Passenger Airbag Off indicator light in the centre console must
come on. In addition to the Airbag Off indicator light, a message is displayed in the instrument cluster:
Check passenger seat adjustment. To determine the status, press F7 or F8 . Then press >> .
10. To check the system, select the Actual values menu under the AWS control unit. Then press >> .
10.1. Select the Weight group (0-4) and Gross weight calibrated options.
10.1.1. If there is no weight on the passenger’s seat, compare values (see table below) using the PIWIS Tester.
The Passenger Airbag Off indicator light in the centre console must not come on.
10.1.2. Place the special tool test weight P 9742 on the passenger’s seat. The Passenger Airbag Off indicator
light in the centre console must come on. Compare values (see table below) using the PIWIS Tester.
10.1.3. Get an assistant with a body weight of more than 55 kg, for example, to sit on the passenger’s seat. The
Passenger Airbag Off indicator light in the centre console must not come on. Compare values (see table
below) using the PIWIS Tester.
11. Read out and erase the fault memories in the Airbag and AWS control unit, perform a test drive and then
read out the fault memories again. If faults are found, determine the cause using the PIWIS Tester and
correct the faults.
as of MY 2003
Country C02, C34, C36
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
ATTENTION
Risk of damage to the soft-look paint coat if the cleaning agents or solvents available as accessories for
cleaning the vehicle interior are used. This also applies to the use of plastic polish from the Tequipment
care set. The contents of these agents etch the paint coat (paint swells, rubber-like texture).
Consequently, the paint coat can separate from the substrate when a mechanical load is applied.
Furthermore, the surface may shine brightly after using the cleaning agents.
→ The following procedure is recommended for the care or cleaning of soft-look paint surfaces.
Information
It is possible to clean heavy soiling by selecting an option from the following cleaning tools and cleaning fluids:
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
70 02 19 Removing and installing front cover (engine
compartment) - as of MY 2003
- Removing front cover (engine compartment)
- Installing front cover (engine compartment)
Installation Location:
1. Remove trim panel on the right.
Installation Location:
1.1. Insert front trim panel on right and left -1a, 1b- underneath the lid seal and position in engine compartment.
1.2. Position fixing clips -2- on support in direction of the click stops and press into the supports.
2.1. Insert rear trim panel -3- underneath the lid seal and position in engine compartment.
2.2. Position fixing clip -2- on the support in the direction of the click stops and press support in.
3. Install trim panel on the left.
3.1. Insert trim panel on the left -4- underneath the lid seal and position
in engine compartment.
3.2. Position the fixing clips -2- on the supports in the direction of the
click stops and press into the supports.
4.1. Insert trim panel on the right -6- underneath the lid seal and
position in engine compartment.
4.2. Position the fixing clips -2- on the supports in the direction of the
click stops and press into the supports.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove rear backrest.→ 724719 Removing and installing rear backrest - "Removing" section.
2. Remove cover for seat connection. → 700319 Removing and installing side trim panel for rear luggage
compartment - "Removing" section
3. Remove C-pillar trim panel.→ 706819 Removing and installing C-pillar trim panel - "Removing" section
4. Remove rear roof trim panel.→ 708519 Removing and installing rear roof trim panel - "Removing" section.
5. Remove D-pillar trim panel. → 706919 Removing and installing D-pillar trim panel - "Removing" section
6. Remove luggage-compartment lining (loadspace cover).→ 700619 Removing and installing luggage-
compartment lining (loadspace cover) "Removing" section
7. Install cover for lock carrier. → 703919 Removing and installing cover for lock carrier - "Installing" section
Installation Location:
1. Unclip end piece.
1.1. Unclip end piece -5- at the marked areas, lift the trim panel slightly
at the rear and lever the clip connection out using an assembly
wedge.
In order to reduce the unclipping forces and thereby the risk of damage during removal, the process must
take place at the accessible connection points using a suitable tool.
Installation Location:
Note
In order to reduce the unclipping forces and thereby the risk of damage during removal, the process must
take place at the accessible connection points using a suitable tool.
6.1. Unclip side trim panel for luggage compartment -1- at marked areas, lift trim panel slightly and use a
screwdriver to lever the clip connection -3- out.
7.1. Unclip side trim panel for luggage compartment -1- at marked areas, lift trim panel slightly and use a
screwdriver to lever the clip connection -3- out.
Note
When removing the backrest, the bearing sleeve -8- may come loose
and catch on the pin.
Installation Location:
1. Check fixing clips.
1.1. Check fixing clips -3, 7- of side trim panel for luggage compartment
for deformation and replace if necessary.
4. Clip side trim panel for luggage compartment into the bodyshell at the marked areas. Make sure that the side
trim panel engages in the retaining clips at the side window -8- .
6.1. Screw in fastening screws -2- at the C-pillar and tighten to the specified tightening torque. → Tightening
torque: 1.5 (1.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
7. Screw in fastening screw.
Installation Location:
8. Check fixing clips.
8.1. Check fixing clips -9, 10- of the end piece for deformation and
replace if necessary.
10. Clip end piece -5- into the bodyshell at the marked areas.
Installing cover for seat connection
1. Check fixing clips
1.1. Check fixing clips -10- of luggage compartment side trim panel for
deformation and replace if necessary.
Subsequent work
1. Install cover for lock support → 703919 Removing and installing cover for lock support - "Installing" section
2. Install luggage-compartment lining (loadspace cover).→ 700619 Removing and installing luggage-
compartment lining (loadspace cover) "Installing" section
3. Install D-pillar trim.→ 706919 Removing and installing D-pillar trim - "Installing" section
4. Install C-pillar trim.→ 706819 Removing and installing C-pillar trim - "Installing" section
5. Install cover for seat connection.→ 700319 Removing and installing side trim panel for rear luggage
compartment - "Installing" section
6. Install rear backrest.→ 724719 Removing and installing rear backrest - "Installing" section.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
70 04 19 Removing and installing insulation for engine
compartment lid - as of MY 2003
- Removing insulation for engine compartment lid
- Installing insulation for engine compartment lid
Installation Location:
1. Open engine compartment lid.
2.1. Carefully insert a screwdriver between the insulation -1- and retaining clips -2- .
Installation Location:
1. Install insulation and clip retaining clips into place.
1.3. Push retaining clips -2- into fixing openings until they can be heard to engage.
2. Close the engine compartment lid.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
70 06 19 Removing and installing luggage compartment trim
(loadspace cover) - as of MY 2003
- Removing luggage compartment trim (loadspace cover)
- Installing luggage compartment trim (loadspace cover)
Installation Location:
1. Disengage loadspace cover -1- from front connection points by
pulling towards the rear.
2. Tighten fastening screws -4- to the specified tightening torque. → Tightening torque: 8 (6 ftlb.) Nm +/-1.5
(1.0 ftlb.) Nm
3. Engage loadspace cover -1- in front connection points by pushing forwards and close loadspace cover.
4. Position tie-down rings -5- .
5. Unfold lashing tie-down ring strap.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove dashboard. → 701819 Removing and installing dashboard - "Removing" section
Note
To prevent damage to the steering column, support the steering column with a suitable object or tie it to the
side with tie-wraps.
2. Unscrew steering column at dashboard bracket. → 481519 Removing and installing steering column -
"Removing" section [9PAAJ1]→ 481519 Removing and installing steering column - "Removing"
section [9PAAD1 9PAAD7]→ 481519 Removing and installing steering column - "Removing"
section [9PAAE1 9PAAE7 9PAAF1]
3. Remove cowl panel cover. → 664419 Removing and installing cowl panel cover - chapter on "removing"
Installation Location:
1. Remove fuse box.
2.2. Remove control unit for tyre pressure monitoring system -5- ( -Arrow B- ) and tie to the side with
connected leads.
3. Unclip wiring harness for parking brake contact switch and remove plug.
3.1. Unclip wire harness -6- on fastening clip -7- -arrow C- . Replace damaged fixing clips -7- .
10. Unclip wire harness for PCM -22- at the fixing clips -23- -Arrow O- .
Replace damaged fixing clips -23- .
11. Unclip wire harness for PCM -22- at the fixing clips -24- -arrow P- .
12. Unclip antenna lines for PCM -25- at the fixing clips -26- and -27- -Arrows Q- . Replace damaged fixing clips
-26- and -27- .
18.1. Pull out bracket -31- from guide in firewall to the rear -arrow T- .
18.2. Pull out bracket -31- upwards over parking brake mechanism -arrow U- .
18.3. Pull out bracket -31- upwards over centre tunnel -arrow W- .
Installing bracket for the dashboard
Installation Location:
1. Insert bracket.
1.3. Insert bracket -31- into guide in the firewall -Arrow C- . When doing
so, insert the strut -35- over the bolts -36- -Arrow D- .
2.1. Align bracket -31- with the markings previously made -Arrows E- .
2.2. Screw in -32- fastening screws.
5.1. Screw in fastening screw -29- and tighten to the specified torque.
→ Tightening torque: 23 (17 ftlb.) Nm +/-3 (2 ftlb.) Nm
6.1. Connect ground straps -18- together with cage -17- -Arrow M- .
6.2. Screw in nuts -19- and tighten to the specified torque. → Tightening torque: 9 (6.5 ftlb.) Nm +/-1 (0.5
ftlb.) Nm
7.1. Clip in wire harness for instrument cluster -21- at the fixing clips -20- -Arrow H- .
8.1. Clip in wire harness for PCM -22- at the fixing clips -24- -Arrow K- .
8.2. Clip in wire harness for PCM -22- at the fixing clips -23- -Arrow I- .
9.1. Clip in antenna lines for PCM -25- at the fixing clips -26- and -27-
-Arrows L- .
10. Install fuse box.
11.1. Insert control unit for tyre pressure monitoring system -5- -Arrow N-
.
12. Connect plug and clip in wire harness for parking brake contact
switch.
12.1. Push on the plug -8- until the locking tabs engage audibly
-arrow O- .
13.1. Insert control unit carrier -10- and support -11- on bracket -Arrow R- and pull downward -Arrow S- .
13.2. Screw in nut -9- and tighten to the specified torque. → Tightening torque: 8 (6.5 ftlb.) Nm +/-1 (0.5 ftlb.)
Nm
14. Screw air-conditioning unit on bracket.
14.1. Screw in fastening screws -13- and tighten to the specified torque.
→ Tightening torque: 10 (7.5 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
Subsequent work
1. Install relay carrier. → 979019 Removing and installing relay carrier, plenum chamber E-box - "Installing"
section
2. Install cowl panel cover. → 664419 Removing and installing cowl panel cover - chapter on "installing"
3. Screw in steering column at dashboard bracket. → 481519 Removing and installing steering column -
"Installing" section [9PAAJ1]→ 481519 Removing and installing steering column - "Installing"
section [9PAAD1 9PAAD7]→ 481519 Removing and installing steering column - "Installing" section [9PAAE1
9PAAE7 9PAAF1]
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Keys T10152
2. Remove trim panel under dashboard on the driver's side → 701919 Removing and installing trim panel under
dashboard - section on "Removing"
3. Remove air vent for door window → 855919 Removing and installing air vent for door window - section on
"Removing" [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ 855919 21 Removing and installing air vent for door
window - section on "Removing" [9PAAD1 9PAAD7].
4. Remove ignition switch. To do this, unscrew the union nut -1- using the appropriate special tool (→
Removing and installing dashboard cover on the driver's side) -arrow A- and remove it -arrow B- .
6. Remove top section of the steering column trim. To do this, adjust the steering column downward and to the
rear.
7. Disengage the holding straps -3- on the top section of the steering column trim -4- using a screwdriver. To
do this, the steering wheel must be turned 90° from the middle position to the left and then 180° to the right.
8. Lift the top section of the steering column trim -4- at the rear
-arrow D- and pull it out of the holding straps -arrow E- .
9. Remove instrument panel cover on the driver's side. To do this, unscrew the fastening screw -5- .
Installing dashboard cover on the driver's side
Installation Location:
1. Insert the cover for the instrument panel on the driver's side -6-
together with the top section of the steering column trim -arrow A- .
3. Install top section of steering column trim. To do this, insert top section of steering column trim -4- into the
holding strap at the front.
4. Push top section of the steering column trim -4- down at the rear
-arrow C- until the holding straps -3- engage audibly.
6. Install ignition switch. To do this, push the ignition switch -2- from the rear through to the front -arrow D- .
7. Put on union nut -1- -arrow E- and screw it in using the appropriate special tool -arrow F- . → Removing
and installing dashboard cover on the driver's side
8. Install air vent for door window → 855919 Removing and installing air vent for door window - section on
"Installing" [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ 855919 23 Removing and installing air vent for door
window - section on "Installing" [9PAAD1 9PAAD7].
9. Install trim panel under dashboard on the driver's side → 701919 Removing and installing trim panel under
dashboard - section on "Installing"
10. Install dashboard moulding on the driver's side.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Keys T10152
Installation Location:
1. Remove trim strips for dashboard on the passenger's side. → Removing trim strips for dashboard on the
passenger's side
2. Remove glove compartment → 681519 Removing and installing glove compartment - section on "Removing"
3. Remove air vent at door. → 855919 Removing and installing air vent at door - section on
"Removing" [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ 855919 21 Removing and installing air vent at door -
section on "Removing" [9PAAD1 9PAAD7]
5. Swivel the cover for the instrument panel on the passenger's side -1- out and down -arrow A- , pull it out
with the holding strap -3- -arrow C- and remove to the rear -arrow B- .
3. Install air vent at door. → Removing air vent at door [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ Removing air
vent at door [9PAAD1 9PAAD7]
4. Install glove compartment. → 681519 Removing and installing glove compartment - section on "Installing"
5. Install trim strips for dashboard on the passenger's side. → Removing trim strips for dashboard on the
passenger's side
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
Note
There must be a smooth transition between the instrument panel and the door trim panels. The instrument
panel should be centred in the vehicle so that the gaps for the door trim panels are the same width on both
sides.
1. Check the installation position of the instrument panel. To do this, check the gap dimension and height
difference -arrows- between the instrument panel -1- and the door trim panels -2- visually and adjust them if
necessary.
2. Unclip the cover of the fuse box.
3. Remove left and right air guide. To do this, unscrew fastening screw
-3- and remove left and right air guide -4- .
5. Unscrew the fastening screws -6- on the instrument panel carrier -7- .
6. Screw out the top fastening screws -8- of the relay carrier until the fastening screws -9- are accessible on the
instrument panel carrier -7- .
7. Unscrew the fastening screws -9- on the instrument panel carrier -7- .
9. Re-check the gap dimension and height difference -arrows- between the instrument panel -1- and the door
trim panels -2- visually.
10. Tighten fastening screws -6- and -9- to the specified tightening torque → Tightening torque: 17 ftlb. +/-2
ftlb. → Tightening torque: 17 ftlb. +/-2 ftlb. .
11. Screw in the top fastening screws -8- on the relay carrier.
12. Fold down the carpet -5- and press on it; use double-sided adhesive tape, if necessary.
9PAAD1, 9PAAD7, 9PAAE1,
9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Removing dashboard
1. Remove instrument panel cover → Removing and installing dashboard cover on driver's side→ Removing
and installing dashboard cover on the passenger's side
2. Remove cover for instrument panel (defroster cover) → 702019 Removing and installing cover for instrument
panel (defroster cover) - section on "Removing"
3. Remove Bose centre speaker → 914019 Removing and installing the front loudspeakers (instrument panel) -
section on "Removing"
4. Remove steering-column switch → 945019 Removing and installing steering-column switch - section on
"Removing"
5. Remove instrument cluster → 902519 Removing and installing instrument cluster - section on "Removing"
6. Remove passenger's airbag unit → 695919 Removing and installing passenger's airbag unit - section on
"Removing"
7. Remove front ashtray → 682019 Removing and installing front ashtray - section on "Removing"
8. Remove display and operator control unit (PCM) → Removing and installing display and operator control
unit (PCM)
9. Remove A-pillar trim → 705719 Removing and installing A-pillar trim - section on "Removing"
10. Remove the device carrier. To do this, unscrew the fastening screws
-2- .
11. Pull the device plugs -1- to the rear -arrow A- until the plugs
-arrows- are accessible.
13. Remove the sheetmetal reinforcement on the passenger's side. To do this, unscrew the fastening screws -4-
.
14. Lift the sheetmetal reinforcement on the front passenger's side -3- and pull it out to the rear -arrow B- .
15. Remove the centre instrument panel cover. To do this, unscrew the fastening screws -6- .
16. Swivel the centre instrument panel cover -5- carefully upward
-arrow C- and then remove it to the rear -arrow D- .
17. Release the instrument panel on the driver's side and at the middle. To do this, unscrew the fastening
screws -7- and -7- .
18. Release the instrument panel on the passenger's side. To do this, unscrew the fastening screws -8- .
19. Carefully pull the instrument panel -9- to the rear -arrow E- until the clip connection in the area of the A-pillar
becomes accessible.
20. Unclip the clip connection -10- on the instrument panel -arrow F- .
21. Carefully pull the instrument panel -9- to the rear -arrow G- out of the retaining clips -11- .
Installing dashboard
Position the instrument panel.
1. To do this, carefully insert the instrument panel -9- -arrow A- until the
clip connection -10- can be clipped into place -arrow C- .
2. Push the instrument panel -9- into the retaining clips -11- -arrow A- . Simultaneously fit the instrument panel
-9- over the instrument panel carrier -12- -arrow B- .
9. Push on the plug -arrows- until the locking tabs engage audibly.
12. Only on USA version: Insert the sheetmetal reinforcement on the passenger's side -3- -arrow G- .
14. Install A-pillar trim → 705719 Removing and installing A-pillar trim - section on "Installing".
15. Install display and operator control unit (PCM) → Removing and installing display and operator control unit
(PCM)
16. Install front ashtray → 682019 Removing and installing front ashtray - section on "Installing"
17. Install passenger's airbag unit → 695919 Removing and installing passenger's airbag unit - section on
"Installing"
18. Install instrument cluster → 902519 Removing and installing instrument cluster - section on "Installing"
19. Install steering-column switch → 945019 Removing and installing steering-column switch - section on
"Installing"
20. Install Bose centre loudspeaker → 914019 Removing and installing front loudspeakers (instrument panel) -
section on "Installing"
21. Install cover for instrument panel (defroster cover) → Removing and installing cover for instrument panel
(defroster cover)
22. Install instrument panel cover → Removing and installing dashboard cover on driver's side→ Removing and
installing dashboard cover on the passenger's side
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
70 19 19 Removing and installing trim under dashboard - as of MY
2003
- Removing trim panel under dashboard
- Installing trim panel under dashboard
Installation Location:
1. Remove dashboard moulding on driver's side.→ 705819 Removing and installing dashboard moulding -
"Removing" section
2. Remove cover under dashboard on driver's side.→ 702219 Removing and installing cover under dashboard
- "Removing" section
4.1. Unclip fuse box cover -1- using a plastic wedge on the retaining clips -2- and swivel it outwards -arrow A- .
4.2. Remove the fuse box cover -1- to the rear -arrow B- .
7.1. Using a screwdriver, carefully unclip the sleeve -8- and ball joint -9-
of the Bowden cable upwards out of the release lever -10- (
-arrow- ).
8. Take off the trim panel under the dashboard on the driver's side.
Removing the cover under the instrument panel on the passenger's side
Installation Location:
1. Remove dashboard moulding on passenger's side.→ 705819 Removing and installing dashboard moulding
on passenger's side - "Removing" section
2. Remove cover under dashboard on the passenger's side. → 702219 Removing and installing cover under
dashboard - "Removing" section
4.2. Open glove compartment -1- , unscrew the fastening screw -4- and remove rubber buffer -3- .
6.1. Unscrew the fastening screws -8- and swivel the trim panel under
the dashboard on the passenger's side -7- downwards (
-arrow C- ). Pull out the trim panel under the dashboard on the
passenger's side -7- over the guide -9- ( -arrow D- ).
8. Remove the trim under the dashboard on the passenger's side -7- .
Installing trim panel under dashboard
Installation Location:
1. Insert the trim panel under the dashboard on the driver's side.
1.1. Insert trim under the dashboard on the driver's side -4- into the
guides -11- -arrow A- .
2. Clip in the bowden cable for
the parking brake release.
3. Push on the plug -6 and 7- until the locking tabs engage audibly
-arrows B- .
4. Install trim under dashboard on the driver's side.
4.1. Insert trim under the dashboard on the driver's side -4- over the
guide -5- -arrow C- .
4.2. Swivel the trim under the dashboard on the driver's side -4- upwards -arrow D- .
5.2. Swivel fuse box cover -1- inward and push it in -arrow F- until the retaining clips -2- engage audibly.
6. Install cover under dashboard on driver's side.→ 702219 Removing and installing cover under dashboard -
"Installing" section
Installing the cover under the instrument panel on the passenger's side
Installation Location:
1. Insert the trim under the dashboard on the passenger's side.
1.1. Move the trim under the dashboard on the passenger's side -3-
until the plug can be plugged in.
2. Push on the plug -10- until the locking tabs engage audibly ( -arrow A- ).
3. Install trim under instrument panel at front passenger's side.
3.1. Insert trim under the dashboard on the driver's side -7- over the
guide -9- ( -arrow B- ).
3.2. Swivel the trim under the dashboard on the passenger's side -3-
upwards ( -arrow C- ).
5.1. Screw in fastening screws -2- and tighten to the specified tightening
torque. → Tightening torque: 1.0 ftlb. +/-0.15 ftlb.
5.3. Insert rubber buffer -3- , screw in fastening screw -4- and tighten to
the specified tightening torque. → Tightening torque: 1.0 ftlb. +/-
0.15 ftlb.
7. Install dashboard moulding on passenger's side.→ 705819 Removing and installing dashboard moulding on
passenger's side - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
The figure → Centre cover shows the centre cover -1A- , the centre cover with sun sensor -1B- and the centre
cover with ParkAssist -1C- .
1. To unclip the centre cover,
insert a plastic wedge under
the centre cover
-1A, 1B or 1C- and lever it up
and out → see figure .
2. In the case of vehicles with
sun sensor or ParkAssist,
disconnect the electric plug
connection.
Centre cover
3. Insert plastic wedge under loudspeaker trim panel on the left and
right -2- and lever it up and out.
7. Remove dashboard cover (defroster cover). To do this, insert a plastic wedge under the dashboard cover
(defroster cover) on the left and right -5- and lever it up and out.
2. Clip cover for dashboard (defroster cover) into place on left and right.
6. Clip loudspeaker trim panel -2- into place on left and right.
7. In the case of vehicles with sun sensor -1B- or ParkAssist -1A- , connect the electric plug connection.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
70 22 19 Removing and installing cover under dashboard - as of
MY 2003
- Removing cover under dashboard
- Installing cover under dashboard
Installation Location:
1. Open door.
3. Disconnect the plug connections and remove cover under dashboard on the driver's side.
3.2. Remove the cover under the dashboard on the driver's side -1- to the rear -arrow B- .
Removing cover under dashboard on the passenger's side
Installation Location:
1. Open door.
Installation Location:
1. Insert cover under dashboard on the driver's side
1.1. Insert cover under the dashboard on the driver's side -1- into the
guides -6- -arrows A- .
2. Connect plug.
2.1. Push on the plug -4, 5- until the locking tabs engage audibly.
3.1. Press the cover under the dashboard on the driver's side -1-
upwards until the fastening clips -3- can be heard to engage
-arrow B- .
Installation Location:
1. Insert cover under dashboard on the passenger's side.
1.1. Insert cover under the dashboard on the passenger's side -1- using
the guides -6- -arrow A- .
2. Connect plug.
2.1. Push on the plug -4, 5- until the locking tabs engage audibly.
3.1. Press the cover under the dashboard on the driver's side -1- upwards until the fastening clips -3- can be
heard to engage -arrow B- .
3.2. Screw in fastening screw -2-
.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Note
In order to reduce the unclipping forces and thereby the risk of damage during removal, the process must
take place at the accessible connection points using a suitable tool.
1. Open front and rear doors.
2. Remove B-pillar trim → 706719 Removing and installing B-pillar trim - section on "Removing"
3. Remove inner door sill trim → 680519 Removing and installing inner door sill trim - section on "Removing"
4. Unclip fuse box cover -1- using a plastic wedge on the retaining clips -2- and swivel it to the outside
-arrow A- .
7. Unclip the securing spring -4- towards the front using a small screwdriver -arrow D- .
8. Remove actuating lever -3- from the release to the inside -arrow E- .
9. Unclip centre trim -5- from the mounting points of the A-pillar trim -6- , from the lower trim -7- and from the
fastening clip -8- on the A-pillar and remove to the rear -arrow F- .
10. Unclip lower trim -7- from the mounting points on the A-pillar and remove to the rear -arrow G- .
2. Clip lower trim -7- into the mounting points on the A-pillar from behind -arrow A- .
3. Starting from behind, clip centre trim -5- into the mounting points of the A-pillar trim -6- , into the lower trim
-7- and into the fastening clip -8- on the A-pillar -arrow B- .
Perform steps 4 and 5 only on the driver's side.
4. Fit securing spring -4- on the actuating lever -3- and press in fully
-arrow C- .
5. Push actuating lever -3- onto the release from the inside -arrow D- and push in until the securing spring
audibly engages.
7. Swivel fuse box cover inward and push it in -arrow F- until the retaining clips -2- audibly engage.
8. Install inner door sill trim → 680519 Removing and installing inner door sill trim - section on "Installing".
9. Install B-pillar trim → 706719 Removing and installing B-pillar trim - section on "Installing"
10. Close front and rear doors
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
3. Starting at the fastening bolt -5- at the top, unclip A-pillar trim from the clip connections.
Installing A-pillar trim
Installation Location:
1. Check fastening clips -8- for deformation; replace if necessary.
2. Insert retaining catches -3- on the A-pillar trim -1- into the fastening clips -2- and the instrument panel guide
slot.
3. Insert the retaining catch -4- into A-pillar side trim at the bottom.
4. Clip A-pillar trim -1- into A-pillar from bottom to top. Make sure that
the fastening bolt reaches into the fastening bore.
5. Screw in fastening screw -6- and tighten to the specified tightening torque. → Tightening torque: 3 ftlb.
+0.25 ftlb.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38,
C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
3. Insert a plastic wedge under the ignition lock collar -1- , lever it out and remove it to the rear -Arrow A- .
4. Insert a plastic wedge under the trim strip on the driver's side -2 and 3- , carefully unclip it and take it off to
the rear -arrow B- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
3. Insert a plastic wedge underneath the trim strip on the passenger's side -1- , carefully unclip it, and take it off
toward the rear -Arrow A- .
4. Insert a plastic wedge underneath the cover for the glove compartment lock -2- , carefully unclip it, and take
it off toward the rear -arrow B- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
70 59 19 Removing and installing front door trim panel - as of MY
2003
- Removing front door trim panel
- Installing front door trim panel
Installation Location:
1. Carefully lever out trim panel for mirror triangle -4- using plastic
wedge and pull forwards -arrows- .
2. Unclip switch -5- out of trim panel for mirror triangle from behind -arrow- .
6. Lever out the trim -3- at the positions -A, B und C- using a plastic
wedge.
8. Unclip front door trim panel -1- at bottom -arrow D- and unhook from sealing channel at top -arrow E- .
9. Unlock plug -8- by operating locking lever -10- and remove from control module -9- .
10. Release plug for door loudspeaker -12- at door loudspeaker -11- and pull it off.
11. Unlock fastening clip for actuating cable for door lock -13- by pressing the locking hook arrows -arrow F- and
disengage from the guide slot arrow -arrow G- .
12. Swivel pin -14- of actuating cable forward by 90° and disengage upward.
13. Remove door trim panel.
Note
The fastening clips have two settings. Before installing the front door
trim panel, the fastening clips must be loosened fully because
otherwise the door trim panel may not engage fully into the door unit
carrier, possibly resulting in noises. The fastening clips must be
pulled to the front position.
Installation Location:
4. Engage pin -14 - of the actuating cable and swivel back by 90°.
5. Insert T-tread of fastening clip -13- into the square hole → see
figure .
7. Connect plug for door loudspeaker -12- to plug connection of door loudspeaker -11- .
8. Connect plug -8- by operating locking lever -10- and lock into position.
9. Hook front door trim panel in sealing channel at top -arrow A- and clip in at bottom -arrow B- . Make sure
that the guide pins -15- engage in the sub-frame.
10. Screw in fastening screws -7 and 7a- and tighten to the specified tightening torque → Tightening torque:
3.0 ftlb. +/-0.5 ftlb. → Tightening torque: 1.5 ftlb. +/-0.5 ftlb. .
11. Position trim -3- at the positions -C, D und E- and clip into armrest.
12. Position the cover -2- at inner door handle and clip into place.
15. Position trim panel for mirror triangle -4- at the door and clip into place.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1. Remove front door trim. → 705919 Removing and installing front door trim - section on "Removing"
Removing insulation
1. Detach insulation at the bonding points and remove it.
Note
To replace the armrest light, the armrest must be removed on vehicles with I Number "9MB comfort courtesy
lights, dimmable".
Installation Location:
Installation Location:
Removing and installing front armrest
Screwing in screws
6. Install door handle.
6.1. Place door handle -5- in position and screw fastening screw -4- in
hand-tight.
Installing insulation
ATTENTION
Danger of material damage when tacking down insulation.
The door trim panel or assembly parts can be damaged when
tacking down insulation.
Staples, 4 mm 00000
Installing insulation
Subsequent work
Subsequent work
1. Install front door trim. → 705919 Removing and installing front door trim - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
70 61 19 Removing and installing cover for door trim panel - as of
MY 2003
- Removing cover for door trim panel
- Installing cover for door trim panel
Installation Location:
Removing cover for rear door trim panel
Installation Location:
1. Carefully lever out cover -1- for door trim panel using a plastic wedge and remove it -arrow A- .
Installation Location:
Installation Location:
1. Check fastening clips.
1.1. Check fastening clips -2- for deformation, replace if necessary.
2. Clip in cover.
2.1. Position cover -1- on the door trim panel and clip it in ( -arrow A- ).
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
70 63 19 Removing and installing inner door opener - as of MY
2003
- Removing inner door opener
- Installing inner door opener
Installation Location:
Note
The diagram and work procedure are displayed on the handle of the front door. This also applies to the
handle on the rear door.
2.1. Carefully lever out cover -2- for armrest using a plastic wedge and
remove it ( -arrow B- ).
3. Remove handle.
Installation Location:
1. Install handle.
3.1. Position the cover -1- on handle and clip into place ( -arrow C- ).
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
70 67 19 Removing and installing B-pillar trim panel - as of MY
2003
- Removing B-pillar trim panel
- Installing B-pillar trim panel
Installation Location:
Note
In order to reduce the unclipping forces and thereby the risk of damage during removal, the process must
take place at the accessible connection points using a suitable tool.
2.2. Guide seat belt mount -3- down and unhook it.
4.1. Unhook trim for B-pillar -1- at front edge on deformation element ( -arrows A- ).
8.1. Guide seat belt mount -3- through slide of B-pillar trim -1- .
2.1. Guide seat belt mount -3- through slide of B-pillar trim -1- .
3.2. Connect plug connection -6- until the locking tab engages audibly (
-Arrows A- ).
5.1. Clip B-pillar trim -1- into interior B-pillar at the bottom at the marked areas.
6. Hook B-pillar trim into place at rear.
6.1. Hook trim for B-pillar -1- into place at rear edge ( -arrow B- ).
6.2. Hook release for seat belt height adjustment into place. → 706719
Removing and installing B-pillar trim - chapter on "Installing"
7.1. Hook B-pillar trim -1- into place on deformation element ( -arrows C- ).
7.2. Check entire B-pillar trim once more to ensure correct installation and adjust if necessary.
8.1. Screw in fastening screw -5- and tighten to the specified tightening torque. → Tightening torque: 4 (3
ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
8.2. Clip cap -4- into the cut-out for the B-pillar trim.
9. Engage seat belt mount at bottom.
9.1. Engage seat belt mount -3- and pull upwards. Spring clamp -3a-
engages independently and locks seat belt mount.
9.2. Check that seat belt mount has engaged properly and repeat
assembly process if necessary.
Installation Location:
1. Move actuator for seat belt height adjustment and adjustment fitting
into assembly position.
1.1. Push actuator for seat belt height adjustment -1- into upper end
position.
1.2. Move adjustment fitting at B-pillar -4- into upper end position.
Note
Assembly instructions for seat belt height adjustment
The operating knob of the seat belt height adjustment must not be
pressed during this installation step.
The seat belt must not be restricted by cable, lines, insulation, etc.
2.1. Insert guide bush -2- into guide pin -3- on adjustment fitting and lay trim panel -4- against B-pillar.
3. Check operation.
3.1. Check function of seat belt height adjustment by actuating it several times. The seat belt height adjuster
must engage into place in one of 5 possible positions (including the uppermost).
3.2. The operating knob of the seat belt height adjustment must automatically return to the upper position after
each operation.
3.3. The seat belt height adjuster must remain in the locked position when pulled abruptly.
3.4. The sash guide must level out on its own in a vertical position or in the direction in which it is worn.
9PAAD1, 9PAAD7, 9PAAE1,
9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
70 68 19 Removing and installing C-pillar trim panel - as of MY
2003
- Removing C-pillar trim panel
- Installing C-pillar trim panel and release for belt height adjustment
Installation Location:
1. Fold down seat cushion of rear seat.
5. Unclip C-pillar trim -1- from side trim -6- at front edge -Arrow B- and unhook at deformation element
-Arrow A- .
7. Remove C-pillar trim in downward direction -E- .
Installing C-pillar trim panel and release for belt height adjustment
4. Hook C-pillar trim -1- onto deformation element -arrow A- and clip into side trim -6- at front edge -arrow B- .
5. Install actuator for height adjustment of seat belt. → 706819 Removing and installing C-pillar trim - chapter
on "Installing"
6. Hook C-pillar trim -1- onto deformation element -Arrow C- and clip into side trim at rear edge -Arrow D- .
7. Screw in fastening screw -3-
and tighten to the specified
tightening torque. →
Tightening torque: 4.0 (3.0
ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
8. Clip cover flap -2- into the cut-out for the C-pillar trim.
9. Position bottom belt fitting -4- , screw in fastening screw -5- and tighten to the specified tightening torque. →
Tightening torque: 50 (37 ftlb.) Nm +4.0 (3.0 ftlb.) Nm
1. Move actuator for seat belt height adjustment and adjustment fitting
into assembly position.
1.1. Push actuator for seat belt height adjustment -1- into upper end
position.
1.2. Move adjustment fitting at B-pillar -4- into upper end position.
Note
Assembly instructions for seat belt height adjustment
The operating knob of the seat belt height adjustment must not be
pressed during this installation step.
The seat belt must not be restricted by cable, lines, insulation, etc.
2.1. Insert guide bush -2- into guide pin -3- on adjustment fitting and lay trim panel -4- against B-pillar.
3. Check operation.
3.2. The operating knob of the seat belt height adjustment must
automatically return to the upper position after each operation.
3.3. The seat belt height adjuster must remain in the locked position
when pulled abruptly.
3.4. The sash guide must level out on its own in a vertical position or in
the direction in which it is worn.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
1. Remove rear roof trim panel. → 708519 Removing and installing rear roof trim panel - section on
"Removing"
6. Unclip D-pillar trim -1- from interior D-pillar at the bottom. To do so, raise trim slightly and lever out the
fastening clips -2- using a screwdriver.
7. Only in vehicles with Bose sound system: Pull off plug -5- from the loudspeaker
Installation Location:
1. Check fastening clips -2- for deformation; replace if necessary.
2. Only in vehicles with Bose sound system: Pull connector -5- away from the speaker
4. Engage rear section of D-pillar trim to rear side trim -arrow C- and
hook into place at rear edge of D-pillar -arrow B- .
5. Clip D-pillar trim -1- into inside of D-pillar at the marked areas -2- .
8. Install rear roof trim panel. → 708519 Removing and installing rear roof trim panel - section on "Installing"
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
1. Carefully lever out cover -2- of inner door handle using a plastic
wedge and remove it.
2. Use a plastic wedge to lever out cover -3- at positions -A, B and C- .
3. Unscrew fastening screws -4- and -4a- .
4. Unclip rear door trim panel -1- at bottom -arrow D- and unhook from
sealing channel at top -arrow E- .
5. Release plug -6- and pull it off the control module -5- .
6. Unlock and pull off the plugs for the door loudspeaker -7- -arrows- .
7. Unlock fastening clip of actuating cable for door lock -8- by pressing the locking hook -arrow F- and
disengage from the guide slot -arrow G- .
8. Swivel pin -9- of the actuating cable forward by 90° and disengage in an upward direction.
Installation Location:
Note
The fastening clips have two settings. Before installing the front door trim panel, the fastening clips must be
loosened fully because otherwise the door trim panel may not engage fully into the door unit carrier, possibly
resulting in noise. The fastening clips must be pulled to the front position.
2. Pull fastening clips -10- to the front position so that they are fully loosened.
3. Positioning door trim panel
4. Engage pin -9- of the actuating cable and swivel back by 90°.
9. Hook rear door trim panel -1- into sealing channel at top -arrow A- and clip in at bottom -arrow B- . Make
sure that the guide pins -12- engage in the sub-frame.
10. Screw in fastening screws -4 and 4a- and tighten to the specified tightening torque. → Tightening torque:
3.0 ftlb. +/-0.5 ftlb. → Tightening torque: 1.5 ftlb. +/-0.5 ftlb.
11. Align cover -3- at the positions -C, D und E- and clip into the armrest.
12. Position cover -2- on inner door handle and clip into place.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Preliminary work
1. Remove rear door trim panel. → 707319 Removing and installing rear door trim panel - section on
"Removing"
Removing insulation
1. Detach insulation at the bonding points and remove it.
Note
To replace the armrest light, the armrest must be removed on vehicles with I Number "9MB comfort courtesy
lights, dimmable".
Installation Location:
Installation Location:
Removing and installing rear armrest
2.2. Drill out any remaining plastic material in the centre of the mounting dome using a drill bit (4 mm).
Screwing in screws
6. Install door handle.
6.1. Place door handle -5- in position and screw fastening screw -4- in
hand-tight.
ATTENTION
Danger of material damage when tacking down insulation.
The door trim panel or assembly parts can be damaged when tacking down insulation.
→ Before tapping in the clamps, press in the insulation at the installation positions with your fingers and make
sure that no underlying components (e.g. wire harness) can be damaged.
→ Only clamps of the specified length may be used.
Staples, 4 mm 00000
Installing insulation
Subsequent work
Subsequent work
1. Install rear door trim panel. → 707319 Removing and installing rear door trim panel - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
70 83 37 Disassembling and assembling front roof console - as of
MY 2003
- Disassembling front roof console
- Assembling front roof console
Installation Location:
Remove front roof console. → 601219 Removing and installing switch for sunroof - section on "Removing"
Note
The repair description relates to a fully equipped roof console.
1. Unscrew fastening screw -1- and take out the sun visor along with the support -2- ( -arrow- ).
2. Unlock connector on garage door opener control unit -arrows A- and pull it off -arrow B- .
3. Unscrew the two fastening screws -2- and remove the control unit -arrow C- .
4. Unscrew the fastening screws -3- and take out the support -arrow D- .
Note
Only if replacing the printed circuit board
5. Turn the sockets of the bulbs for interior lighting to the left -arrow A- and remove them -arrow B- .
6. Pull the piece of plastic foam off the plug connection -arrow A- .
10. Unscrew the four fastening screws -4- and remove printed circuit board for interior lighting -arrow- .
11. Carefully pull the connector off the printed circuit board -arrow B- .
12. Press in the two clips -arrows A- and press the reading light out in a
downward direction -arrow B- .
15. Turn the printed circuit board -arrow A- and pull the connector off the printed circuit board (P- & SOS
button) -arrow B- .
17. Turn the printed circuit board (garage door opener) -arrow A- and pull the two connectors off the printed
circuit board -arrows B- .
22. Release the lighting unit -arrow C- and press it down and out
-arrow D- .
23. Release the nine locking tabs -arrows A- and press the two covers down and out -arrows B- .
24. Release the nine locking tabs -arrows A- and carefully press the cover down and out -arrow B- .
25. Press the clip together -arrows A- and carefully remove the spring -arrow B- .
26. Remove the contact bridge -1- ( -arrow C- ).
27. Carefully pull the holder out of the locking mechanism -2- ( -arrows D- ) and pull the switch -3- down and out
-arrow E- .
28. Carefully press switch trim for sun blind to the inside -arrow A- and remove it -arrow B- .
29. Release the switch trims -arrows A- and remove them -arrows B- .
30. Unscrew both fastening screws -8- .
31. Move spring -1- for the push-button -2- to the left -arrow A- and remove it -arrow B- .
34. Press the right bearing pin at the edge inwards -arrow A- -arrow A- , pivot the shelf down -arrow B- and
remove it -arrow C- . Push the spring through the opening at the same time -arrow D- .
35. Pull off the bearing sleeve -arrow A- and remove the spring -arrow B- .
Assembling front roof console
Installation Location:
Note
The springs for the shelf are assigned to the right and left side. Given this, please make sure to observe the
installation position of the springs.
1. Place the springs on the pivot axis -1- and the retaining pivot -2- ( -arrows- ).
2. Connect the bearing sleeve with the contact surface -3- pointing towards the spring at the pivot axis. Make
sure that the flat edge -4- of the contact surface is facing downwards.
3. Insert the fully opened shelf at the left side -arrow A- . Push the spring through the opening -arrow B- .
4. Insert the spring at the right side through the opening -arrow C- .
5. Press in the bearing pin at the underside -arrow D- , then press the
shelf into the roof console -arrow E- until the bearing pin with the
bearing sleeve engages securely.
6. Press in the closing damper -arrow A- until you feel the locking tabs -B- engage.
8. Insert the spring -2- ( -arrow B- ), move it to the right -arrow C- , and screw down using the two fastening
screws -8- .
Note
The switch trims can be installed in only one position.
9. Press in the switch trims -arrow A- until you feel the locking tabs -B-
engage.
11. Place the switch trim in installation position and press it in -arrow B- until it engages securely in the retaining
pivot -1- .
Note
Position the cover in such a
way that the sliding switch
contacts are pointing towards
the shelf.
13. Position the sliding switch -1- in the cover in such a way that the
pictogram is aligned with that on the adjacent switch trims -2- .
14. Turn the cover with the sliding switch around.
15. Insert the holder -1- through the sliding switch -2- ( -arrow A- ) and
press it carefully into the bracket -arrow B- until the locking tabs are
felt to engage -C- .
17. Connect the spring to the sliding switch -a- ( -arrow E- ) until the locking tabs are felt to engage -arrows F- .
18. Place the switch trim in installation position and press it in -arrow A- until the nine locking tabs engage
securely -arrows B- .
19. Engage the two covers at the back -A- and press in at the front edge -arrow B- until the locking tabs (three
on each cover) are felt to engage -C- . Make sure that the covers are positioned correctly at the frame of the
switch trims -D- .
20. Insert the light ring into the cover and align the two markings -arrow- .
21. Align the lighting unit with the
sun blind switch -1- and press
it in -arrow A- until the locking
tabs -B- are felt to engage.
22. Engage the cover at the roof console -C- and press it in -arrow D- until the four locking tabs -E- are felt to
engage.
24. Connect the two connectors on the printed circuit board until they are
felt to engage -arrows A- .
25. Turn the printed circuit board around -arrow B- and screw down with four fastening screws -6- .
26. Connect the connector to the printed circuit board -arrow A- until it engages securely.
27. Turn the printed circuit board around -arrow B- and screw down with three fastening screws -5- .
28. Connect the connector to the printed circuit board until they engage securely -arrow A- .
29. Place the printed circuit board in installation position -arrow B- and screw down with three fastening screws
-7- .
30. Insert the microphone -arrow A- until the two locking tabs -B- are felt to engage.
31. Place the reading light in installation position and press it in -arrow A- until the two clips -B- engage
securely.
32. Place the switch in installation position and press it in carefully -arrow A- . Make sure that all three locking
hooks -B- engage at the switch.
33. Connect the plug connection -arrows A- and slide the piece of plastic foam over the plug connection
-arrow B- .
34. Insert the sensor into the roof console frame -A- until the two locking hooks -B- are felt to engage. Ensure it
is seated properly.
35. Attach the connector to the printed circuit board -arrow A- until it
engages securely.
36. Place the printed circuit board in installation position -arrow B- and
screw down with four fastening screws -4- .
Note
Only if replacing the printed circuit board
37. Insert bulbs into the printed circuit board -arrow A- and tighten -arrow B- .
38. Place the holder in installation position -arrows A- and screw down with three fastening screws -3- .
39. Place the control unit on the holder -arrow B- and screw down with both fastening screws -2- .
40. Push in connector -arrow C- until the locking tabs -D- are felt to engage.
41. Insert the sun visor and holder -2- ( -arrow- ) and secure with the
fastening screw -1- .
42. Install front roof console. → 601219 Removing and installing switch
for sunroof - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
1. Remove A-pillar trim. → 705719 Removing and installing A-pillar trim - "Removing" section
2. Remove the B-pillar trim. → 706719 Removing and installing B-pillar trim - "Removing" section
3. Remove C-pillar trim. → 706819 Removing and installing C-pillar trim - chapter on "removing"
4. Remove rear roof trim panel. → 708519 Removing and installing rear roof trim panel - "Removing" section
5. Remove D-pillar trim panel. → 706919 Removing and installing D-pillar trim panel - "Removing" section
6. Remove sun visors. → 682319 Removing and installing sun visor - "Removing" section
7. Roof console → 601219 Removing and installing switch for sunroof - "Installing" section
8. Remove front grab handles. → 683519 Removing and installing grab handle - chapter on "Removing"
9. Remove sides of reading lights. → 964719 Removing and installing bulb for reading light - "Removing"
section
Removing headliner
Installation Location:
1. Open cover -7- and unscrew fastening screw -8- .
2. Fold down headliner -1- at front edge.
4.1. Unclip fastening part of headliner -12- from the bodyshell -13- at the
back.
4.2. Remove headliner -1- and guide out of vehicle through tailgate opening.
Note
Additional assembly operations must be performed on vehicles with sunroof or roof assembly. → 708419
Removing and installing roof trim panel - "Removing" section
Installing headliner
Installation Location:
1. Check fastening clips -14- of headliner for deformation, and replace if
necessary.
2. Guide headliner -1- into the vehicle through tailgate opening and position at roof frame.
3. Clip fastening part for roof liner -12- into the bodyshell -13- at the
back.
6. Screw in new fastening screw -8- and tighten to the specified tightening torque. → Tightening torque: 9 (6.5
ftlb.) Nm
7. Close cover -7- .
Note
Additional assembly operations must be performed on vehicles with
sunroof or roof assembly. → 708419 Removing and installing roof
trim panel - "Removing" section
2. Clip in headliner -1- using fastening clips -14- close to sunroof cut-out.
1. Insert both sections of the frame -16- in the roof assembly cutout and connect by moving the clamps -15- .
Note
Centre the clamps -15- in the middle on the gap between both frames
-16- .
Subsequent work
Subsequent work
1. Install rear handles. → 683719 Removing and installing rear handle - "Installing" section
2. Install front grab handles. → 683519 Removing and installing grab handle - chapter on "Installing"
3. Install sides of reading lights. → 964719 Removing and installing bulb for reading light - "Installing" section
4. Install sides of sun visors. → 682319 Removing and installing sun visor - "Installing" section
5. Install roof console. → 601219 Removing and installing switch for sunroof - "Installing" section
6. Install A-pillar trim. → 705719 Removing and installing A-pillar trim - "Installing" section
7. Install B-pillar trim. → 706719 Removing and installing B-pillar trim - "Installing" section
8. Install C-pillar trim. → 706819 Removing and installing C-pillar trim - chapter on "installing"
9. Install D-pillar trim. → 706919 Removing and installing D-pillar trim panel - "Installing" section
10. Install rear roof trim panel. → 708519 Removing and installing rear roof trim panel - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
3. Unclip headliner at marked positions. To do so, lift the lining slightly at the rear and lever the clip connection
-2- out using a screwdriver.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
3. Unscrew fastening screw -2- on both sides at the guide elements -3- .
4. Lift guide elements -3- -Arrow A- and push all the way to the front over the sliding/tilting roof trim -1-
-Arrow B- . Simultaneously push the sliding/tilting roof trim -1- to the rear -Arrow C- .
5. Lift the sliding/tilting roof trim -1- -Arrow D- and remove over the guide elements -3- -Arrow E- .
Installation Location:
1. Insert sliding/tilting roof trim -1- and push back completely over the
guide elements -3- -Arrow A- .
2. Lift the guide elements -3- -Arrow B- and push over the sliding/tilting roof trim -1- -Arrow C- .
Simultaneously push the sliding/tilting roof trim -1- to the front -Arrow D- .
3. Screw in fastening screws -2- on both sides at the guide elements -3- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
3. Unclip centre window frame trim -2- from the rear lid and from the
side window frame trim -3- at the marked positions. To do so, raise
the trim slightly and lever out the clip connection -5- using a
screwdriver.
4. Move the rear lid to the intermediate position shown → see figure .
5. Unclip side window frame trim -3- from the rear lid and from the rear lid trim at the marked positions -1- . To
do so, raise the trim slightly and lever out the clip connection using a screwdriver.
6. Close rear lid. The rear window -12- remains open.
Installation Location:
1. Unclip cover for rear wiper motor -11- at the marked positions. To do so, raise the trim slightly and lever out
the clip connection using a plastic wedge.
2. Open the rear lid.
6. Lever the lock cover -8- out of the rear lid lining -1- using a screwdriver.
8. Remove finger plate -9- from the rear lid lining -1- .
9. Unclip the rear lid lining -1- from the rear lid at the marked positions. To do so, raise the trim slightly and
lever out the clip connection using a screwdriver.
Installing lining for rear lid
Installation Location:
1. Check clips for deformation; replace if necessary.
2. Clip the rear lid lining -1- onto the rear lid at the marked positions.
3. Insert handle liner -9- into the rear lid lining -1- .
4. Screw in fastening screw -10- .
5. Clip lock cover -8- into the rear lid lining -1- .
7. Insert side lights -6, 7- into the rear lid lining and clip into place.
8. Check sheetmetal retaining clips → see figure for deformation; replace if necessary.
9. Clip cover for rear wiper motor -11- onto the rear lid at the marked positions.
2. Check sheetmetal retaining clips -5- and clips for deformation; replace if necessary.
3. Clip top window frame trim -4- at the places indicated ( -circle marks- ) on the rear lid.
4. Move the rear lid to the intermediate position shown → see figure .
5. Clip the side window frame trim -3- onto the rear lid and the rear lid lining at the marked positions.
6. Clip centre window frame trim -2- onto the rear lid at the marked positions.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
70 91 19 Removing and installing lid hinge trim - as of MY 2003
- Removing lid hinge trim
- Installing lid hinge trim
Installation Location:
1. Remove hinge cover.
1.1. Insert a plastic wedge between the body and hinge cover -1- .
1.2. Carefully unclip and remove the hinge cover -1- .
2. Remove outer hinge cover.
3.2. Swivel out inner hinge cover -4- -Arrow D- and remove it.
4.2. Open wiring duct -5- -(Arrows F)- and remove the cover -6- -(Arrow G)- .
4.3. Remove wiring duct -6- from wire harness -(Arrow H)- .
5. Remove wiring duct on rear window hinge.
5.1. Release wiring duct -7- -(Arrow I)- and remove it from rear window hinge -(Arrow K)- .
5.2. Release cover -8- -(Arrows L)- and remove it -(Arrow M)- .
5.3. Remove wiring duct -7- from
wire harness -(Arrow N)- .
Installing lid hinge trim
Installation Location:
1. Install wiring duct on rear window hinge.
1.1. Guide wiring duct -7- over wire harness -(Arrow A)- .
1.3. Place the wiring duct -7- on the rear window hinge until the locking
tabs engage audibly ( -(Arrow D)- ).
2. Install wiring duct on lid hinge.
2.1. Guide wiring duct -5- over wire harness -(Arrow E)- .
2.2. Press in the cover -6- until the locking tabs engage audibly -(Arrow F)- .
2.3. Connect wiring duct -5- to the rear window hinge -(Arrow G)- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
ATTENTION
Danger of injury and damage to property as a result of incorrect handling of airbag units! Always observe
the safety regulations for handling airbag units → Safety regulations for handling airbag and... .
The airbag unit must always be deposited so that the airbag opening faces upward!
If removed for an extended period, the airbag unit must be kept in a locked place!
After the battery is disconnected, always wait for 1 minute before disconnecting the airbag plugs.
In the case of faulty fore-and-aft or vertical adjustment, the seat can only be removed together with the seat
frame. → Removing and installing front seat frame
Installation Location:
1. Move backrest all the way forward. Move front seat all the way up and all the way forward.
2. Unlock the covers -Arrows C- and remove the rear seat rail caps -Arrows D- .
4. Pull out seat belt cap at the front side -A- and take out to the front -B- .
5. Unlock retaining clip on the belt end fitting with a suitable screwdriver -Arrow A- .
6. Push belt end fitting over the retaining pin -Arrow B- until the lug under the retaining pin relieves the clip.
7. Remove belt end fitting from the retaining pin -Arrow A- and pull seat belt out through the belt guide
-Arrow B- .
8. Move the driver's seat back fully and lower rear seat area.
9. Remove ignition key. Disconnect battery. Route or isolate the ground strap so that all contact with a ground
carrier (e.g. body, seat frame) is avoided → 90 Work instructions after disconnecting the battery.
10. Unlock the covers -Arrow A- and remove the front seat rail caps -Arrow B- .
15. Press protective cover on airbag plug down -Arrow A- and hold in this position.
16. Unlock airbag connector
-Arrow B- and remove
-Arrow C- .
DANGER
Incorrect information for AWS control module.
Passenger's airbag is triggered differently.
→ If the passenger's seat was removed and re-installed, the AWS control module must be calibrated.
→ If the seat bracket was replaced, the AWS control module must be calibrated.
→ If the AWS control module was replaced, the AWS control module must be calibrated.
3. Insert airbag plug -Arrow A- until the lock -B- is felt to engage.
4. Insert plug into seat control module -Arrow A- until the locking tabs
-B- are felt to engage.
ATTENTION
Risk of material damage to screw connections for seat and seat frame!
→ 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!
8. Move front seat all the way back. Screw in front fastening screws -4-
only until the seat rails touch the seat frame.
9. Move front seat all the way forwards and screw seat to seat frame at
rear -3- → Tightening torque: 45 (33 ftlb.) Nm .
10. Push rear caps onto the seat rails -Arrows A- and press down the
covers -Arrows B- until these are felt to engage.
11. Move front seat all the way back and screw seat to seat frame at the
front -4- → Tightening torque: 45 (33 ftlb.) Nm .
12. Push front caps onto the seat rails -Arrows C- and press down the
covers -Arrows D- until these are felt to engage.
13. Push seat belt through the belt guide on the seat -Arrow A- .
14. Position belt end fitting on the retaining pin -Arrow B- and pull
upward -Arrow C- until the retaining clip locks audibly.
15. Engage seat belt cover on seat trim -Arrow A- and push in
-Arrow B- until it can be felt to engage.
16. Carry out work instructions after disconnecting the battery → 90
Work instructions after disconnecting the battery.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove front seat → 720119 Removing and installing front seat - section on "Removing".
2. Remove AWS control module → 696819 Removing and installing AWS control module - section on
"Removing".
1. Lift front trim at the rear -Arrow A- , then unclip and remove it -Arrow B- .
2. Unclip and remove side trim -Arrow C- .
ATTENTION
Risk of material damage to screw connections for seat and seat frame!
→ 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!
DANGER
Incorrect information for AWS control module.
Passenger's airbag is triggered differently.
→ If the passenger's seat was removed and re-installed, the AWS control module must be calibrated.
→ If the seat bracket was replaced, the AWS control module must be calibrated.
→ If the AWS control module was replaced, the AWS control module must be calibrated.
Note
Calibration applies only for vehicles of MY '06 with country equipment (USA, Canada, Mexico).
7. Clip front trim into place -Arrow A- until it can be felt to engage.
Subsequent work
Subsequent work
1. Install AWS control module → 696819 Removing and installing AWS control module - section on "Installing".
2. Install front seat → 720119 Removing and installing front seat - section on"Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
72 16 19 Removing and installing front seat trim - as of MY 2003
- Removing front seat trim
- Installing front seat trim
Installation Location:
1. Move front seat forward until fastening screws of front trim are accessible.
2. Pull out seat belt cap at the front side -Arrow A- and take out to the
front -Arrow B- .
5. Unlock the two connectors -Arrow B- and remove from the seat adjustment switch -Arrows C- .
Note
The number of plugs can vary, depending on the equipment.
7. Push pins of expanding clips -B- out towards the inside and remove
the expanding clips.
Note
If the retaining bracket becomes loose from the side trim during
removal, it must be refitted to the side trim for installation.
10. Push pins of expanding clips -B- out towards the inside and remove the expanding clips.
11. Release inner trim at front using a commercially available screwdriver -Arrow A- .
12. Pull trim at bottom outward -Arrow B- and lift it up and out -Arrow C- .
1. Engage inner side trim onto the seat frame from above -Arrow A- .
2. Push lock inward -Arrow C- , then push in the trim at the bottom -Arrow B- .
8. Insert the two plugs into the seat adjuster switch -A- and swivel trim back to the installation position -B- .
Note
The number of plugs can vary, depending on the equipment.
10. Insert seat belt cap on the front trim -Arrow A- and push in
-Arrow B- until it can be felt to engage.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
ATTENTION
Danger of injury and damage to property as a result of incorrect handling of airbag units! Always observe
the safety regulations for handling airbag units → 69 Safety regulations for vehicles with airbags and belt
tensioners.
The airbag unit must always be deposited so that the airbag opening faces upward!
If removed for an extended period, the airbag unit must be kept in a locked place!
After the battery is disconnected, always wait for 1 minute before disconnecting the airbag plugs.
→
Installation Location:
1. Remove front seat → 720119 Removing and installing front seat - section on "Removing".
Note
Before the battery is disconnected when removing the front seat, the seat must be moved into top position and
the backrest must be tipped back by approx. 45°.
2. Remove backrest cover → 722619 Removing and installing cover for backrest - section on "Removing".
3. Remove inner and outer seat trim → 721619 Removing and installing front seat trim - section on "Removing".
Note
The number of plugs and wiring harnesses can vary, depending on the front seat equipment.
4. Counter plastic strip -1- of spring core and use a release lever -2-
removal tool, universal NR.21 to unclip wiring harnesses from the
spring core -arrows- .
5. Push back lock of the side airbag plug -arrow A- and remove the plug
-arrow B- . Then unlock side airbag plug on the seat frame -arrow C-
and push out towards the front -arrow D- .
6. Unlock ground plug -1- and central plug -2- -arrows A- and remove
both plugs -arrows B- .
8. Using a screwdriver, lever backrest out of the centring bushings at the inner side -arrow- , turn upward and
remove from the installation position.
9. Hold backrest in upright position and push outer side of seat cushion inwards -arrow A- . Subsequently pull
the wiring harnesses upward -arrow B- out of the seat frame.
10. Remove padding for backrest → 741719 Removing and installing padding for backrest - section on
"Removing".
11. Remove lumbar support → 723419 Removing and installing lumbar support - section on "Removing".
12. Remove motors for lumbar adjustment → 723619 Removing and installing motor for lumbar adjustment -
section on "Removing".
13. Remove side airbag → 696319 Removing and installing side airbag - section on "Removing".
14. Remove wiring harness for backrest → 975619 Removing and installing wiring harness for backrest - section
on "Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 975619 21 Removing and installing wiring
harness for backrest - section on "Removing" [9PAAJ1].
2. Install side airbag → 696319 Removing and installing side airbag - chapter on "Installing".
3. Install motors for lumbar adjustment → 723619 Removing and installing motor for lumbar adjustment -
chapter on "Installing".
4. Install lumbar support → 723419 Removing and installing lumbar support - chapter on "Installing".
5. Install padding for backrest → 741719 Removing and installing padding for backrest - chapter on "Installing".
6. Engage backrest at inner side for installation of the wiring harnesses -arrow- . Make sure that the backrest
cannot tilt backward or forward.
9. Engage backrest into the centring bushings at outer side -arrows- and
screw in both fastening screws but do not tighten.
Note
Make sure that the plastic sleeve is inserted between the top centring
bushing and the backrest.
10. Using a screwdriver, lever inner side of backrest outward -Arrow A- , then shift backrest until bores engage
on the centring bushings -B- .
11. Screw in both fastening screws on inner side -3- , then tighten fastening screws on both sides -3, 4- →
Tightening torque: 34.5 (26 ftlb.) Nm .
12. Insert ground plug of side airbag -1- and central plug of backrest -2- into seat wiring harness until they can be
felt to engage.
13. Clip airbag plug onto spring core -Arrow A- until lock -B- can be felt to
engage.
14. Join airbag connectors -Arrow C- until the lock -D- can be felt to engage.
16. Install inner and outer seat trim → 721619 Removing and installing front seat trim - chapter on "Installing".
17. Install backrest cover
→ 722619 Removing and
installing cover for backrest -
chapter on "Installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
72 26 19 Removing and installing cover for backrest - as of MY
2003
- Removing cover for backrest
- Installing cover for backrest
Installation Location:
1. Pull plastic strips on seat frame forwards and disengage -Arrow A- .
3. Using a screwdriver -C- , lever out the clip -D- and remove rubber strap from clip.
4. Disengage cover at side trim on inside -Arrow A- and outside
-Arrow B- .
5. Pull cover rearward at the top to unclip it -Arrow A- and lift it up and
out -Arrow B- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
72 34 19 Removing and installing lumbar support - as of MY 2003
- Removing lumbar support
- Installing lumbar support
Installation Location:
1. Remove lumbar adjustment cable.
→ 723619 Removing and installing motor for lumbar adjustment - chapter on "Removing"
→ 723619 Removing and installing motor for lumbar adjustment - chapter on "Removing"
Note
Unclip lumbar support at top first. If the lumbar support is first disengaged at the bottom and turned towards
the back, the top clips may break.
3. Using a commercially available screwdriver, lever out lumbar support at the top -arrow- .
4. Fold lumbar support forward.
3. Fold lumbar support up and push into fastening clips -arrows- until they can be felt to engage.
→ 723619 Removing and installing motor for lumbar adjustment - chapter on "Installing"
→ 723619 Removing and installing motor for lumbar adjustment - chapter on "Installing"
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
72 36 19 Removing and installing motor for lumbar adjustment
and lumbar curvature - as of MY 2003
- Removing motor for lumbar adjustment and lumbar curvature
- Installing motor for lumbar adjustment and lumbar curvature
Installation Location:
Note
Before removing the motor, move the lumbar support as far down as possible in order to take the strain off
the cable. If it is not possible to disengage the cable when the lumbar support is in the top position or
blocked, the cable may have to be cut.
1. Remove padding for front backrest. → 741719 Removing and installing padding for front backrest - chapter
on "Removing"
2. Remove side airbag. → 696319 Removing and installing side airbag - chapter on "Removing"
4. Pull cable upward and remove cable sleeve from mount -Arrow A- .
5. Disengage cable at the lumbar support -B- .
6. Bore out rivets -arrows- on outside and remove motor for lumbar
adjustment with holder.
4. Disengage cable of lumbar curvature adjuster from the lower guide -arrows- .
5. Disengage cable. To do this, fold the cable upward -arrow A- and pull it up and out -arrow B- .
6. Bore out rivets -arrows- on outside and remove motor for lumbar
curvature with holder.
1. Install motor for lumbar adjustment with holder and secure to backrest frame with pop rivets -arrows- .
4. Push the plug onto the adjusting motor -arrow- until the lock can be
felt to engage.
1. Install motor for lumbar curvature with holder and secure to backrest
frame with pop rivets.
2. Engage cable. To do this, insert the cable nipple into the opening from above -arrow A- and fold it down
-arrow B- .
5. Push the plug onto the adjusting motor -arrow- until the locks can be
felt to engage.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
72 47 19 Removing and installing rear backrest - as of MY 2003
- Removing rear backrest
- Installing rear backrest
Installation Location:
Installation Location:
1. Unlock back seats -3, 4- and fold forward by 90°.
2. Only for 2/3-split folding backrest: To undo the belt fitting unscrew the fastening screw -5- and lay seat belt
mount -6- to one side.
3. Only for vehicles with heated seats: Release seat heating plug connection -7- -arrow A- and disconnect
-arrows B- .
4.1. Remove rear headrests, unlock backrests -1,2- and fold fully forward.
5. Remove safety bracket.
Note
Make sure that the bearing sleeve -11- does not become loose and tilt.
Removing bushing for centre bearing
Installation Location:
1. At the joint of bearing shells -14- , insert a screwdriver between shell and shaft bolt -13- .
Installation Location:
1. Clip in bearing shells. Place both bearing shells -14- on the shaft bolt -13- .
Installing rear backrest
Installation Location:
1. Clip any bearing sleeves -12- that may have become unclipped
during removal into the backrests -1,2- .
4. Insert centre shaft bolt of backrest -13- into the centre bearing in -direction of arrow- .
7. Fold backrests -1, 2- up fully and engage in locks. Insert rear headrests.
8. Only for vehicles with heated seats: Push together the seat heating plug connection -7- , until the locking
tabs can be heard to engage -arrow A- .
9. Only for 2/3-split folding backrest: Position seat belt mount -6- .
10. Screw in fastening screw -5- and tighten to the specified tightening torque. → Tightening torque: 37 ftlb. +/-
3.0 ftlb.
11. Fold back seats -3, 4- fully towards the rear and engage in locks.
ATTENTION
Safety-related bolts!
Always replace fastening
screws for seat belt mount
after customer service and
reworking.
Never make alterations to
the micro-encapsulated
screws, which have a
negative effect on the bond
(e.g. using lubricant,
loosening bolts and
screwing them down again).
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Installation Location:
Installation Location:
ATTENTION
Danger of material damage to seat bolts!
→ The fastening screws for seats are coated and must be replaced after being unscrewed.
→ Before screwing in the new fastening screws, clean the thread holes with an M 10 tap!
1. To position the rear seats, unfold hinge parts on the rear seats and
place seats in a raised position → see figure .
2. Screw in fastening screws -3- , -3- and -3- and tighten to the
specified tightening torque. → Tightening torque: 50 (37 ftlb.) Nm
+10 (7.5 ftlb.) Nm
3. Only for vehicles with seat heater: Clip in plug -Arrow A- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
72 63 19 Removing and installing lock for 1/3-split folding rear
backrest - as of MY 2003
- Removing lock for 1/3-split folding rear backrest
- Installing lock for 1/3-split folding rear backrest
Installation Location:
1. Folding rear backrest forward
3.2. Remove cover of lock for rear backrest -3- by pulling it forwards
-Arrow C- .
2. Screw in fastening screws -8- and tighten to the specified torque. → Tightening torque: 20 (15 ftlb.) Nm +/-
2 (1.5 ftlb.) Nm
5. Screw in fastening screws -4- , → Tightening torque: 4.5 (3.5 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm Screw in
fastening screw -5- . → Tightening torque: 2.5 (2.0 ftlb.) Nm +/-0.2 (0.2 ftlb.) Nm
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
72 63 19 Removing and installing lock for 2/3-split folding rear
backrest - as of MY 2003
- Removing lock for 2/3-split folding rear backrest
- Installing lock for 2/3-split folding rear backrest
Installation Location:
1. Fold rear backrest forward.
2. Remove net partition: Pull net partition -1- out to the right -Arrow A- .
3. Unclip cover for rear backrest -4- at fastening clips -Arrow C- and pull out to the left -Arrow D- .
4. Undo fastening screws -2- .
2. Screw in and tighten fastening screws -12- . → Tightening torque: 20 (15 ftlb.) Nm +/-2 (1.5 ftlb.) Nm
4.1. Insert cover of lock for rear backrest -7- -Arrow C- . The release
lever guides -13- must engage perfectly in the supports of the
locking mechanism -14- .
5. Screw in fastening screws -8- -9- and tighten to the specified torque. → Tightening torque: 4.5 (3.5 ftlb.)
Nm +/-0.5 (0.5 ftlb.) Nm → Tightening torque: 2.5 (2.0 ftlb.) Nm
6. Insert cover for rear backrest -4- -Arrow D- and clip in at the fastening clips -Arrow E- .
7. Push on retaining clips -6- - the springs -arrows- must be pointing left, to the centre of the vehicle.
9. Screw in and tighten fastening screws -2- . → Tightening torque: 8 (6 ftlb.) Nm +/-1 (0.5 ftlb.) Nm
10. Insert net partition -1- to the left -Arrow G- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
72 80 19 Removing and installing headrest - as of MY 2003
- Removing headrest
- Installing headrest
Removing headrest
Removing headrest
Installation Location:
1. Push adjusting knob -A- and pull headrest up as far as possible -Arrow B- .
2. Push limit stop in -C- and pull headrest out in upward direction -Arrow D- .
Installing headrest
Installing headrest
1. Push headrest into headrest guides -arrow- . Push headrest down -arrow- until locking tab engages at limit
stop.
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Installation Location:
Overview of switch for seat adjustment
Subsequent work
Subsequent work
1. Install front seat trim and insert both plugs at seat adjustment switch until they can be heard to engage.
→ 721619 Removing and installing front seat trim - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove front seat. → 720119 Removing and installing front seat - "Removing" section
WARNING
Danger of injury and material damage if airbag units are not handled correctly!
→ Always observe the safety regulations for handling airbag units. → Safety regulations for handling airbags
and...
→ The airbag unit must always be stowed so that the airbag opening faces upwards!
→ If removed for an extended period, the airbag unit must be kept in a locked place!
→ Switch off ignition and leave ignition key in. Disconnect battery. Route or isolate the ground strap so that all
contact with a ground carrier (e.g. body, seat frame) is avoided. → Work instructions after disconnecting the
battery.
→ After the battery is disconnected, always wait for 1 minute before disconnecting the airbag plugs.
Note
Before removing the motor, move seat height up fully, then lower it slightly again so that the height
adjustment is not tensioned.
Note
Only disconnect the plug axially from the positioning motor. Otherwise the retaining lugs can break off and a
secure plug lock cannot be guaranteed.
Installation Location:
Loosening motor
2. Unscrew the front fastening screws -Arrows 1 and 2- and place the retaining bracket with the plugs to one
side.
Loosening motor
4. Unscrew both fastening screws -Arrows 4- and pull out the holder.
Loosening holder
Removing engine
5. Push motor backwards until the toothed segment is touching the bend -Arrow A- of the contour.
Removing motor
Installing motor
2. Insert front fastening screw -Arrow 1- with the retaining bracket.
Installing retaining bracket Installing retaining bracket
3. Screw in fastening screw -Arrow 1- , but do not tighten it.
Installing motor
6. Install holder and tighten with the fastening screws -Arrows 4- . → Tightening torque: 23 (17 ftlb.) Nm
7. Tighten fastening screws for motor -Arrows 1 and 3- and retaining bracket -Arrow 2- . → Tightening
torque: 9.7 (7.0 ftlb.) Nm → Tightening torque: 4.5 (3.5 ftlb.) Nm
Inserting connector
Subsequent work
Subsequent work
1. Install front seat. → 720119 Removing and installing front seat - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
72 93 19 Removing and installing control unit for memory seat
adjustment - as of MY 2003
- Removing control unit for memory seat adjustment
- Installing control unit for memory seat adjustment
- Initialising and locking control unit for memory seat adjustment
Installation Location:
Overview of control unit for memory seat adjustment
1. Release covers -Arrows A- and remove front seat rail cover caps -Arrows B- .
2. Release covers -Arrows C- and remove rear seat rail cover caps -Arrows D- .
3. Move front left seat back and up as far as possible. Move backrest fully forward.
5. Fold the carpet sections forward and remove the two fastening screws -Arrows 1- .
6. Fold the seat back as far as possible. With the seat in its folded position, move the seat forward again using
the fore-and-aft adjustment.
Removing front seat trim and folding Removing front seat trim and folding
seat back seat back
1. Push in the connectors -Arrows A- until the locking tabs -B- are felt
to engage.
Inserting connector
4. Push in the connector -Arrow A- until the locking tabs -Connector B- are felt to engage.
ATTENTION
Risk of material damage to screw connections for seat and seat
frame!
→ 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!
2. Use seat adjustment switch to tilt backrest completely forwards (as far as the stop).
3. Keep switch pressed in this position (approx. 5 seconds) until you hear a signal tone on the instrument
cluster. The control unit is now initialised.
The Cayenne comes with either a large or small memory package, depending on the vehicle equipment. The
corresponding memory package must therefore be locked in the control unit following initialisation.
ATTENTION
Risk of material damage if control unit is not locked correctly
→ The control unit can be locked only once. Given this, the memory package that corresponds to the vehicle
equipment must be selected before locking the control unit.
→ If the small memory package is inadvertently locked on a vehicle with a large memory package, only the
scope of the small memory package can be monitored (no electrical steering column or belt height
adjustment monitoring!). This does not impair steering column or belt height adjustment.
Note
The control units for the driver's and front passenger's seat are identical.
The control unit for the passenger's side is automatically coded correctly and does not need to be locked.
The control units cannot be switched, e.g. a passenger control unit that has already been locked cannot be
installed on the driver's side.
It is not possible to switch driver's sides in vehicles with different memory packages.
2. Select Cayenne as the vehicle type and confirm with the >> key.
3. Use the ↑ ↓ keys to select Driver's seat memory or Passenger's seat memory and confirm your selection by
pressing >> .
4. Use the ↑ ↓ keys to select Large memory package or Small memory package and confirm by pressing
>> .
5. Select Lock in the function selection and confirm with the F8 key.
6. To complete the locking process, switch the ignition off and on and then erase the fault memory.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove front seat. → 720119 Removing and installing front seat - "Removing" section
2. Remove seat-belt buckle. → 692419 Removing and installing seat-belt buckle - "Removing" section
3. Remove front backrest frame. → 721919 Removing and installing front backrest frame - "Removing" section
Installation Location:
ATTENTION
Danger of injury and material damage if airbag units are not handled correctly! Always observe the safety
regulations for handling airbag units. → Safety regulations for handling airbag and....
The airbag unit must always be deposited so that the airbag opening faces upward!
If removed for an extended period, the airbag unit must be kept in a locked place!
Remove ignition key. Disconnect the battery and cover battery terminal. → General information on
vehicle battery [9PAAD1 9PAAD7]→ General information on vehicle battery [9PAAE1 9PAAE7
9PAAF1 9PAAJ1].
After the battery is disconnected, always wait for 1 minute before disconnecting the airbag plugs.
Installation Location:
_
1. Place padding and cover on seat frame and align with seat frame.
Subsequent work
Subsequent work
1. Install front seat trim. → 721619 Removing and installing front seat trim - "Installing" section
2. Install front backrest frame. → 721919 Removing and installing front backrest frame - "Installing" section
3. Install front seat-belt buckle. → 692419 Removing and installing front seat-belt buckle - "Installing" section
4. Install front seat. → 720119 Removing and installing front seat - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Remove padding for front seat. → 741019 Removing and installing padding for front seat - chapter on
"Removing"
Note
Only in cars with seat heating!
2. Release plug connection -Arrow A- and disconnect it -Arrows B- .
3. Loosen staples -a- together with cover for padding on right and left
-arrow- .
Note
Release seat cover from the padding, starting from the outside.
Installation Location:
1. Place cover on the padding -arrow- and align with contour of
padding.
Note
Fasten seat cover to the padding, starting from the inside.
2. Fasten cover to the padding using cushion clip pliers NR.130 -2- and new cushion clips 00000 -b- .
3. Fasten cover to the padding right and left using staple gun NR.163 -3- and new staples.
Note
Only in cars with seat heating!
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
74 17 19 Removing and installing padding for front backrest - as
of MY 2003
- Removing padding for front backrest
- Installing padding for front backrest
Installation Location:
1. Remove headrest. → 728019 Removing and installing headrest -chapter on "Removing"
2. Remove front backrest frame. → 721919 Removing and installing front backrest frame - "Removing" section
3. Insert screwdriver (width 2 mm) from inside into bore above locking tab.
4. Press screwdriver in direction of arrow -Arrow A- and release locking tab -B- .
Note
The cover can only be removed together with the padding. Make sure not to damage the padding when
removing it.
8. Pull padding with cover towards the front at the bottom -Arrow C- and remove in upward direction -Arrow D-
.
Note
In vehicles with heated seats, the electric wiring must also be removed.
1. Line up cover of padding at top and sides in such a way that seams
of cover fit into recesses of the padding -arrow- .
2. Push padding with cover over backrest frame from above -Arrow A- and push towards backrest frame at
bottom -Arrow B- .
Note
In vehicles with heated seats, the electric wiring must also be laid.
3. Pull rubber strap back -Arrow C- and engage on backrest frame -Arrow D- .
5. Pull back of cover in and engage on backrest frame with plastic strips
-arrows- .
Note
Start with the top plastic strips, then the bottom strips and finally
engage the side strips.
6. Push headrest guides into backrest frame until they can be felt
engaging.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
1. Remove padding for backrest. → 741719 Removing and installing padding for front backrest - chapter on
"Removing"
Note
Only in cars with seat heating!
Note
Detach covering, starting from the outside of the padding.
4. Cut open cushion clips -a- with side cutters -1- and remove cover
from padding -arrow- .
Note
Fasten covering to the padding, starting from the middle.
2. Fasten cover to the padding using cushion clip pliers NR.130 -2- → 741919 Removing cover for front
backrest - chapter on "Installing" and new cushion clips -a- .
3. Pull the retaining straps to the rear through the openings in the
padding -arrow- .
Note
Only in cars with seat heating!
4. Push together plug connection -Arrows A- until the locking tabs -B-
are felt to engage.
5. Install padding for backrest. → 741719 Removing and installing
padding for front backrest - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove PCM. → 911019 Removing and installing display and operator control unit (PCM) - "Removing"
section [9PAAJ1]→ 911019 Removing and installing display and operator control unit (PCM) - "Removing"
section [9PAAE1 9PAAE7 9PAAF1]
Installation Location:
Overview of seat-heating switch
1. Reach into the opening for the radio unit or display and operator
control unit, press the two securing clips -Arrows 1- together and
remove the switch -Arrow 2- towards the front.
Removing switch
2. Press latch on connector and pull off.
Pulling off connector
Note
Ensure that the switch is fitted securely.
Plugging in connector
2. Push switch into the mounting -arrow- until the holders disengage.
Installing switch
Subsequent work
Subsequent work
1. Install the PCM. → 911019 Removing and installing display and operator control unit (PCM) - "Installing"
section [9PAAJ1]→ 911019 Removing and installing display and operator control unit (PCM) - "Installing"
section [9PAAE1 9PAAE7 9PAAF1]
2. Install radio. → 912419 Removing and installing car radio - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove the trim from under the instrument panel. → 701919 Removing and installing trim under instrument
panel - chapter on "Removing"
Installation Location:
Overview of relay for seat heating
Installing relay
2. Press the relay carrier into the holder -Arrow A- until the locking lugs
are felt to engage -Arrows B- .
Subsequent work
Subsequent work
1. Install brake light switch holder. → 481519 Removing and installing steering column - chapter on
"Installing" [9PAAJ1]→ 481519 Removing and installing steering column - chapter on "Installing" [9PAAD1
9PAAD7]→ 481519 Removing and installing steering column - chapter on "Installing" [9PAAE1 9PAAE7
9PAAF1]
2. Install trim under the instrument panel. → 701919 Removing and installing trim under instrument panel -
chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
74 26 19 Removing and installing regulator for rear seat heating -
as of MY 2003
- Removing regulator for rear seat heating
- Installing regulator for rear seat heating
Installation Location:
Overview of regulator for rear seat heating
Unclipping cover
2. Unscrew fastening screws -Arrows 1- and remove tray together with retaining bracket -arrow- .
Pulling off connector Removing compartment with retaining
3. Release both connectors -Arrow A- and pull them off -Arrow B- . bracket
Removing regulator
1. Insert regulator from the inside -Arrow A- until locking tabs are felt to
engage -Arrow B- .
Inserting regulator
2. Push in the lock -Arrow A- , then insert the connector -Arrow B- until the locking tab -a- is felt to engage in
the opening -b- .
3. Fit tray into the console -arrow- and secure tray and retaining bracket -C- with fastening screws -Arrows 1- .
4. Clip in the cover -arrows- until the locking tabs are felt to engage.
Installing and securing tray Inserting connector
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Clipping in cover
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
74 27 19 Removing and installing control unit for seat heating - as
of MY 2003
- Removing control unit for seat heating
- Installing control unit for seat heating
- Test plan for the seat heating
Installation Location:
Overview of control unit for seat heating
1. Release covers -Arrows A- and remove front seat rail cover caps -Arrows B- .
2. Release covers -Arrows C- and remove rear seat rail cover caps -Arrows D- .
3. Move front left seat back and up as far as possible. Move the backrest fully forward.
5. Fold the carpet sections forward and unscrew both fastening screws -Arrows 1- .
6. Fold the seat back as far as possible. With the seat in its folded position ( -Arrow B- ), move the seat
forward again using the fore-and-aft adjustment ( -Arrow C- ).
Removing seat rail covers Removing seat rail covers
Removing front seat trim and folding Removing front seat trim and folding
seat back seat back
1. Push in control unit -Arrow A- until locking hooks are felt to engage
-Arrows B- .
Inserting connector
ATTENTION
Risk of material damage to screw connections for seat and seat frame!
→ 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!
Folding seat forward and tightening
3. Move seat in folded position backwards ( -Arrow A- ) and fold forward ( -Arrow B- ).
7. Push cover caps onto the rear seat rails -Arrows A- and press down the covers -Arrows B- until they
engage audibly.
8. Push cover caps onto the front seat rails -Arrows C- and press down the covers -Arrows D- until they
engage audibly.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove cover for front seat. → 741319 Removing and installing cover for front seat - chapter on "Removing"
The heating elements for the lower leg support -1- and side bolsters
-2- are connected by electrical leads and can only be replaced
together.
The heating element is sewn into the cover in the area of the seat
cushion -3- and can only be replaced together with the cover.
Remove the heating elements with care, otherwise the padding will be
damaged.
Allocation of heating elements
If necessary, carefully warm the heating elements with a hot-air gun. The temperature must not exceed 50°C!
Installation Location:
Overview of heating element for front seat
1. Remove the side bolster heating elements -2- starting from the rear
-Arrows A- .
2. Remove the lower leg support heating element -1- starting from below -Arrows B- .
Note
Install the heating elements starting from the right or left side bolster.
2. Remove protective film and stick heating element -a- - starting from
the front edge -Arrow A- - onto the padding -Arrow B- .
Subsequent work
Subsequent work
1. Install cover for front seat. → 741319 Removing and installing cover for front seat - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
74 29 19 Removing and installing heating element for backrest -
as of MY 2003
- Removing heating element for backrest
- Installing heating element for backrest
Installation Location:
1. Remove cover for front backrest.
Note
The heating elements beneath the neck rest -1- and backrest side
bolsters -2- are connected by electrical leads and can only be
replaced together.
The heating element is sewn into the covering in the area of the
backrest surface -3- and can only be replaced together with the
covering.
Remove the heating elements with care, otherwise the padding will
be damaged.
If necessary, carefully warm the heating elements with a hot-air gun. The temperature must not exceed 50 °
C!
2. Remove the backrest side bolster heating elements -2- starting from
below -Arrows A- .
3. Remove the heating element under the neck rest -1- starting from the
rear -Arrows B- .
Note
Install the heating elements starting from the right or left backrest side bolster.
2. Remove protective film and stick heating element -a- , starting from
the top edge -A- , onto the padding -Arrow B- .
3. Remove protective film and stick heating element -b- , starting from
the attached heating element -Arrow C- , onto the padding
-Arrow D- .
4. Affix heating element -b- in the area of the neck rest from front to
rear -Arrow E- .
5. Remove protective film and stick heating element -c- , starting from
the top edge -F- , onto the padding -Arrow G- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Remove cover for rear seat → 745019 Removing and installing cover for rear seat - chapter on "Removing"
The heating element is sewn into the cover in the area of the seat
cushion -2- and can only be replaced together with the cover.
Remove the heating elements with care, otherwise the padding will
be damaged.
If necessary, carefully warm the heating elements with a hot-air gun. Allocation of heating elements
The temperature must not exceed 50°C!
Installation Location:
Overview of heating element for rear seat
Note
Stick on the heating elements individually.
2. Remove protective film and, starting from the rear edge, stick heating element -Arrows A- onto the padding
-Arrows B- .
Install cover for rear seat → 745019 Removing and installing cover for rear seat - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Remove cover for rear backrest. → 745319 Removing and installing cover for rear backrest - chapter on
"Removing"
Note
The backrest side bolster heating elements -1- are connected by an
electrical lead and can only be replaced together.
The heating element is sewn into the cover in the area of the backrest
surface -2- and can only be replaced together with the cover.
Remove the heating elements with care, otherwise the padding will
be damaged.
If necessary, carefully warm the heating elements with a hot-air gun. Allocation of heating elements
The temperature must not exceed 50°C!
Installation Location:
1. Carefully remove the heating element, starting from the top -arrows-
.
Note
Stick on the heating elements individually.
Install cover for rear backrest. → 745319 Removing and installing cover for rear backrest - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
74 49 19 Removing and installing padding for 1/3-split folding rear
seat - as of MY 2003
- Removing padding for 1/3 split folding rear seat
- Installing padding for 1/3 split folding rear seat
Installation Location:
1. Remove rear seat. → 724819 Removing and installing rear seat - chapter on "Removing"
2. Lever out seal -2- on cover for rear seat -1- by inserting a plastic
wedge into the front right corner -Arrow A- .
3. Pull piping -2- of cover for rear seat -1- out completely in direction of arrow.
4. Release wire harness for seat heater (only for vehicles with seat heater): Press grommet -3- with connector
-4- out of the seat frame -Arrow B- .
5. Remove padding: Remove seat frame -5- from padding with cover -1- -Arrow C- .
6. Remove cover for seat → 745019 Removing and installing cover for rear seat - chapter on "Removing"
2. Fasten wire harness for heated seats (only for vehicles with heated
seats): Insert connector -4- into the seat frame and fit the grommet
-3- -Arrow A- .
3. Install padding: Place seat frame -5- on the padding with cover -1- and align -Arrow B- .
4. Press piping -2- of cover for rear seat -1- completely into the seat frame in direction of arrow -Arrow C- .
5. Install rear seat. → 724819 Removing and installing rear seat - chapter on "Installing"
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
74 49 19 Removing and installing padding for 2/3-split folding rear
seat - as of MY 2003
- Removing padding for 2/3-split folding rear seat
- Installing padding for 2/3-split folding rear seat
Installation Location:
1. Remove rear seat. → 724819 Removing and installing rear seat - chapter on "Removing"
2. Lever out piping -2- of cover for rear seat -1- by inserting a plastic
wedge into the front left corner -Arrow A- .
3. Pull piping -2- of cover for rear seat -1- out completely in direction of arrow.
4. Release wire harness for seat heater (only for vehicles with seat heater): Release connector -4- -Arrow B-
and pull it off -Arrow C- .
5. Press grommet -3- with connector -4- out of the seat frame -Arrow D- .
6. Remove padding: Remove seat frame -5- from padding with cover -1- -Arrow E- .
7. Remove cover for rear seat. → Removing cover for 2/3-split folding rear seat
Installing padding for 2/3-split folding rear seat
Installation Location:
1. Install cover for rear seat. → Installing cover for 2/3-split folding rear seat
2. Fasten wire harness for seat heater (only for vehicles with seat
heater): Insert connector -4- into the seat frame and fit the grommet
-3- -Arrow A- .
3. Push connector -4- into the fastening clip -Arrow B- until the locking tab -Arrow C- engages audibly.
4. Place seat frame -5- on the padding with cover -1- and align -Arrow D- .
5. Press piping -2- of cover for rear seat -1- completely into the seat frame in direction of arrow -Arrow E- .
6. Install rear seat. → 724819 Removing and installing rear seat - chapter on "Installing"
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
Installation Location:
Removing cover for 1/3-split folding rear seat
3. Remove cover.
3.1. Cut open the cushion clips -2- in the order shown -a to c- at the designated areas -circle marks- using
side cutters and remove the cover -3- from the padding -Arrow C- . The remaining pieces of the cushion
Installing cover for 1/3-split folding rear bench
Installation Location:
1. Installing cover: Place cover -3- on the padding -Arrow A- and align
with contour of padding.
Installation Location:
Installing cover for 1/3-split folding rear seat
3.1. Push together the plug connection -1- -Arrows B- until the locking tab audibly engages -Arrow C- .
4. Install padding for rear bench. → 744919 Removing and installing padding for rear bench - chapter on
"Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
-4- - Cushion clip pliers NR.130 Gr. 2.4; Workshop Equipment Manual
-2- - Cushion clips - Spare part Gr. 8; Parts Catalogue
Installation Location:
Removing cover for 2/3-split folding rear seat
Installation Location:
1. Install cover: Place cover -3- on the padding -Arrow A- and align with contour of padding.
Installation Location:
Installing cover for 2/3-split folding rear seat
3. Connect plug connection (only for vehicles with heated seats): Push
together the plug connection -1- -Arrows B- until the locking tab
audibly engages -Arrow C- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Technical values
Tightening torques
Installation Location:
1. Remove backrest. → 724719 Removing and installing rear backrest - "Removing" section
2. Remove locking mechanism for rear backrest. → 726319 Removing and installing locking mechanism for
rear backrest - chapter on "Removing"
3. Removing headrest
6. Removing headrest guides: Insert screwdriver (width 2 mm) from inside into bore above locking tab.
7. Press screwdriver in direction of arrow -Arrow B- and release locking tab -Arrow C- .
9. Remove padding for backrest: Lever out piping -4- of cover for seat -5- with a plastic wedge at the upper left
corner -Arrow E- .
10. Pull piping -4- of cover for backrest -5- out completely in the direction of the arrow.
11. Pull cover for backrest -5- over the pin -6- -Arrow F- .
12. Pull cover for backrest -5- over the holder for child-lock button -7- -Arrow G- .
13. Remove backrest frame -8- from the padding with cover for backrest -5- -Arrow H- .
14. Remove cover for rear backrest. → 745319 Removing and installing cover for rear backrest - chapter on
"Removing"
Installing padding for 1/3-split folding rear backrest
Installation Location:
1. Install cover for rear backrest. → 745319 Removing and installing cover for rear backrest - chapter on
"Installing"
2. Place backrest frame -8- on the padding with cover for backrest -5-
and align -Arrow A- . In doing so, pull cover for backrest -5- over the
holder for child-lock button -7- -Arrow C- .
3. Pull cover for backrest -5- over the pin -6- -Arrow D- .
4. Press piping -4- of cover for backrest -5- completely into the backrest
frame in direction of arrow -8- -Arrow B- .
Note
The headrest guide with the headrest release is installed at the left side; the locking tabs of both headrest guides
are facing inwards.
5. Installing headrest guides: Press in headrest guides -3- -Arrows E- , until the locking tabs engage audibly.
8. Install locking mechanism for rear backrest → 726319 Removing and installing rear backrest - chapter on
"Installing"
9. Install backrest. → 724719 Removing and installing rear backrest - "Installing" section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Preliminary work
2. Remove lock for rear backrest: → 724719 Removing and installing rear backrest - section on "Removing"
3. Remove armrest with cover (rear): → 745519 Removing and installing armrest with cover (rear) - section on
"Removing"
Installation Location:
Removing padding for 2/3-split folding rear backrest
3. Removing headrest guides: Insert screwdriver (width 2 mm) from inside into bore above locking tab.
4. Press screwdriver in direction of arrow -Arrow B- and release locking tab -Arrow C- .
9. Detach plastic strip -8- of covering for backrest -6- on backrest frame -Arrow I- .
10. Open front lid -9- -Arrow K- .
12. Detach plastic strips -8- of covering for backrest -6- -Arrows M- .
14. Lever out piping -11- of cover for seat -6- with a plastic wedge at the upper right corner -Arrow O- .
15. Pull piping -11- of cover for backrest -6- out completely in the direction of the arrow.
16. Pull covering for backrest -6- over the pin -12- -Arrow P- .
17. Pull covering for backrest -6-
over the holder for child-lock
button -13- -Arrow Q- .
18. Remove backrest frame -14- from padding with cover -6- -Arrow R- .
Installation Location:
1. Install cover for rear backrest: → 745319 Removing and installing cover for rear backrest - chapter on
"Installing"
2. Install padding: Place backrest frame -14- on the padding with cover for backrest -6- and align -Arrow A- . In
doing so, pull cover for backrest -6- over the holder for child-lock button -13- -Arrow C- .
3. Pull cover for backrest -6- over the pin -12- -Arrow D- .
4. Press piping -11- of cover for backrest -6- completely into the backrest frame in direction of arrow -14-
-Arrow B- .
9. Engage plastic strip -8- of cover for backrest -6- on backrest frame -Arrow I- .
Insert cover for backrest -6- over the holding strap -7- -Arrow K- and fold over -Arrow L- .
14. Screw in and tighten fastening screws -2- . → Tightening torque: 4.5 (3.5 ftlb.) Nm +/-0.5 (0.5 ftlb.)
Sekunden
Subsequent work
3. Instal backrest: → 724719 Removing and installing rear backrest - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
Tools
Installation Location:
Installation Location:
1. Remove padding for rear backrest. → 745219 Removing and installing padding for rear backrest - chapter
on "Removing"
2. Only for vehicles with seat heating: Push the seat heating wiring harness -2- through the cover to the inside
-Arrow C- .
Installation Location:
1. Remove padding for 2/3-split folding rear backrest. → 745219 Removing and installing padding for 2/3-split
folding backrest - chapter on "Removing"
Installation Location:
3. Release plug connection -1- ( -Arrow A- ) and disconnect it
-Arrow B- .
4. Cut open the cushion clips -3- in the sequence shown -a to d- and at the positions indicated -circle marks-
using side cutters and remove the cover -4- from the padding -Arrow D- . Remove remaining pieces of the
cushion clips 00000 -3- .
Installing cover for rear backrest
Installation Location:
Installation Location:
1. To install cover: place cover on the padding -Arrow A- and align with
the contour of the padding.
2. Fasten cover using the cushion clip pliers NR.130 -5- and new cushion clips 00000 -3- in the order shown
-a to c- .
3. Only for vehicles with heated seats: Push plug connection -1- together -Arrows B- until the locking lug is felt
to engage -Arrow C- .
4. Push the seat heating wiring harness -2- through the cover to the outside -Arrow D- .
Installation Location:
1. Place cover -4- on the padding -Arrow A- and align with the contour
of the padding.
Installation Location:
Installation Location:
4. Push the seat heating wiring harness -2- through the cover to the outside -Arrow D- .
5. Install padding for 2/3-split folding backrest. → 745219 Removing and installing padding for 2/3-split folding
backrest - chapter on "Installing"
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
74 55 19 Removing and installing armrest with cover - as of MY
2003
- Removing armrest with cover (rear)
- Installing armrest with cover (rear)
Installation Location:
1. Remove backrest. → 724719 Removing and installing rear backrest - "Removing" section
3. Swivel the armrest cover -2- out over the backrest frame -Arrow B- .
4. Unclip locking tabs -3- of armrest cover -2- at the backrest frame -4- -Arrow C- and remove downwards
-Arrow D- .
6. Release retaining clip -6- with a plastic wedge -Arrow F- and pull over pin -7- -Arrow G- .
7. Close armrest with cover -1- by approx. 45° and unhook with the pin -7- from the guide -8- -Arrow H- .
8. Unhook armrest with cover -1- with the pin -9- from the guide -10- and remove -Arrow I- .
1. Install armrest with cover (rear): Insert armrest with cover -1- with the
pin -9- in the guide -10- -Arrow A- .
2. Position armrest with cover -1- with the pin -7- on the guide -8- and insert -Arrow B- .
3. Push retaining clip -6- over the pin -7- until it engages fully -Arrow C- .
6. Swivel the armrest cover -2- in over the backrest frame -Arrow G- .
8. Install backrest. → 724719 Removing and installing rear backrest - "Installing" section
9PAAD1, 9PAAD7, 9PAAE1,
9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
74 56 19 Removing and installing load-through provision - as of
MY 2003
- Removing load-through provision
- Installing load-through provision
Installation Location:
1. Folding over rear seat and left rear seat back
3. Swivel the armrest cover -2- out over the backrest frame -Arrow B- .
4. Unclip locking tabs -3- of armrest cover -2- at the backrest frame -4- -Arrow C- and remove downwards
-Arrow D- .
7. Unclip cover of load-through provision -7- -circle marks- and remove -Arrow G- .
8. Unclip load-through provision -8- -Arrow H- , press out to the rear -Arrow I- and pull up and out -Arrow K- .
Installing load-through provision
Installation Location:
1. Insert load-through provision -8- -Arrow A- and push forward, until
the locking tabs -arrow- audibly engage -Arrow B- .
2. Install cover of load-though provision: Insert cover of load-through provision -7- -Arrow C- and clip in
-circle marks- .
3. Close front lid -6- -Arrow D- .
5. Insert armrest cover -2- from below -Arrow F- and clip onto the backrest frame using the locking tabs -3-
-Arrow G- .
6. Swivel the armrest cover -2- in over the backrest frame -Arrow H- .
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
WARNING
Danger of material damage and damage to health when handling extraction and filling systems!
→ Before connecting the filling system to the air-conditioning, make sure that the manual shut-off valves are
closed.
→ Before disconnecting the filling system from the air-conditioning, make sure that the process is complete so
that no refrigerant can escape into the atmosphere.
→ After the purified refrigerant has been filled into an external compressed gas bottle from the filling system,
the manual shut-off valves on the bottle and on the filling system should be closed.
→ Do not expose the filling system to moisture or use in a damp environment. Shut off the power supply at the
filling system before carrying out maintenance work.
2
→ An extension cable with a cross-sectional area of at least 2.5 mm should be used only when absolutely
necessary.
→ In the case of fire, the external bottle should be removed.
→ Fill the oil extracted from the air-conditioning system into a suitable closable container (the refrigerant oil
contains small quantities of refrigerant).
→ The filling system must be secured to prevent rolling.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Remove glove compartment. → 681519 Removing and installing glove compartment - chapter on "removing"
Removing servomotor
Note
The heater servo motor - right temperature - is located on the right air conditioning unit.
Switch ignition off and remove ignition key before starting work.
1. Unscrew the fastening screw of the right heat exchanger cover and
unclip the cover.
2. Disconnect plug connection of Unscrewing fastening screw of the
temperature sensor. right heat exchanger cover
Installing servomotor
1. Place the servo motor on the retainer plate and screw down using
the fastening screws -Pfeile B- . → Tightening torque: 1.0 ftlb.
Note
Switch on ignition and carry out the service position menu, Drive links menu with the Porsche System Tester
in the Climatronic.
As an alternative, the servo motors can also be powered with 12 volts until they have reached the correct
position. Always use the circuit diagram for this.
Note
Subsequent work
Subsequent work
Install glove compartment. → 681519 Removing and installing glove
compartment - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Drain engine coolant. → 193817 Draining and topping up with coolant (includes bleeding) - chapter on
"draining"
2. Unclip cover for instrument panel into place on left and right. → 701619 Removing and installing dashboard
cover - chapter on "Removing"
3. Remove front footwell vent on left and right. → 853419 Removing and installing air duct - chapter on
"Removing"
4. Remove Kessy control unit. → 966619 Removing and installing Kessy/immobilizer control unit - chapter on
"Installing"
5. Remove vehicle electrical system control unit. → 971019 Removing and installing vehicle electrical system
control unit - chapter on "Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 971019 21 Removing
and installing vehicle electrical system control unit - chapter on "Removing" [9PAAJ1]
6. Remove relay carrier. → 979019 Removing and installing relay carrier, plenum chamber E-box - chapter on
"Removing"
Installation Location:
Overview of heat exchanger
3. Pull the retaining clips -Arrows A- of the coolant supply line and return line downward.
Note
Line the driver's footwell with very absorbent material.
4. Pull the interior carpet away from the coolant lines and put in a
suitable collecting container.
5. Slowly pull out the lines from the heat exchanger -Arrows B- and
drain the coolant into the collecting container.
Note
There is a retaining pin on the left side above the heat exchanger which joins the lower holding tray (where
the heat exchanger is located) to the air conditioning unit.
As soon as the retaining pin has been pulled out, the heat exchanger with the holding tray can be folded
down.
8. Turn retaining pin out of the latch -Arrow 1- and pull out -Arrow 2- .
9. Fold down holding tray with heat exchanger.
1. Insert heat exchanger carefully into the holding tray. Make sure not to
damage the heat exchanger plates on the retaining stays in the
holding tray.
Note
Always replace O-rings.
3. Insert the coolant supply line and return line -Arrows B- into the heat exchanger.
4. Push on the retaining clips -Arrows A- until the clips click into place.
4.1. Install relay carrier.
→ 979019 Removing and
installing relay carrier,
plenum chamber E-box -
chapter on "Installing"
4.3. Install Kessy control unit. → 966619 Removing and installing Kessy/immobilizer control unit - chapter on
"Installing".
4.4. Top up engine coolant. → 193817 Draining and refilling coolant (includes bleeding) - chapter on "refilling".
4.5. Install front footwell vent on right and left. → 853419 Removing and installing air duct - chapter on
"Installing"
6. Screw down the fastening screw of the heat exchanger holding tray
on the left and right side. → Tightening torque: 1.0 ftlb.
7. Clip in right cover and screw down with the fastening screw. →
Tightening torque: 1.0 ftlb.
Subsequent work
Subsequent work
Clip cover for instrument panel into place on left and right. → 701619 Removing and installing dashboard cover -
chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove rear spoiler upper part. → 665819 21 Removing and installing rear spoiler - chapter on "removing"
2. Remove left D-pillar trim panel. → 706919 Removing and installing D-pillar trim panel - "removing" chapter
3. Remove rear roof trim panel. → 708519 Removing and installing rear roof trim panel - chapter on "removing"
Installation Location:
Overview of antenna for auxiliary heater
2. Remove rubber sleeve from rear spoiler -Arrow B- and unwind the
adhesive tape -Arrow C- .
3. Pull out the antenna through the rubber sleeve -Arrow D- .
11. Pull out the antenna. If necessary, push antenna from the pneumatic
spring housing.
1. Pull antenna from the centre to the pneumatic spring housing -Arrow A- .
2. Plug in connector -Arrow B- until the locking tab -Arrow C- is felt to engage.
8. Fasten the antenna to the rubber sleeve with adhesive tape -Arrow B- .
9. Insert rubber sleeve into rear spoiler -Arrow C- and fasten the antenna with adhesive tape -Arrow D- ..
10. Lay wiring harness in wiring duct and push on cover -Arrow A- until locking tabs -Arrows B- are felt to
Antenna for auxiliary heater
engage.
11. Push wiring duct onto hinge -Arrow C- until locking tabs are felt to engage.
Subsequent work
Subsequent work
1. Install rear spoiler upper part. → 665819 23 Removing and installing rear spoiler - chapter on "installing"
2. Install rear roof trim panel. → 708519 Removing and installing rear roof trim panel - chapter on "installing"
3. Install left D-pillar trim. → 706919 Removing and installing D-pillar trim panel - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Note
The remote control for the auxiliary heater can only be taught using the Porsche System Tester.
Switching from Heating to Fan can only be set on the control module. The pre-set mode is started by
actuating the remote control.
Installation Location:
Overview of remote control for auxiliary heater
1 - ON button
2 - LED
3 - OFF button
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Press >>
to continue.
3. Using the →| key, move from the vehicle type to the control units.
4. Select Auxiliary heater with the cursor keys and press the >> key.
5. Select Teach remote control with the cursor keys, press the >> key, and follow the instructions on the
Porsche System Tester.
6. Once the SEND message appears on the remote control, press the OFF button -3- within 5 seconds, until
the message Saved appears. The remote control is now taught.
Switching the auxiliary heater on and off with the remote control
1. Press the ON button -1- for approx. 2 seconds. The LED -2- turns green.
1 - ON button
2 - LED
3 - OFF button
Switching the auxiliary heater off with the remote control
1 - ON button
2 - LED
3 - OFF button
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
DANGER
Danger of fire!
Note
The auxiliary heater is ready for operation even with the ignition switched off.
The auxiliary heater will operate for 30 minutes. This cannot be changed.
Note
The combustion chamber of the auxiliary heater is cleaned after it is switched off. Given this, wait at least 2
minutes before switching the auxiliary heater on again using the ON/OFF button.
Installation Location:
Overview of timer for auxiliary heater
2. Switch auxiliary heater off. To do this, press the ON/OFF button -8- again.
Installation Location:
Overview of timer for auxiliary heater
2. Activate the change heat/ventilation function. To do this, press the TIMER button -7- .
3. Adjust the auxiliary heater. To do this, press the + button -9- and wait 10 seconds until the two symbols
Auxiliary heater -5- and Auxiliary ventilation -1- have stopped flashing. The auxiliary heater function is
activated the next time the ON/OFF button -8- is pressed.
4. Adjust the auxiliary ventilation. To do this, press the - button -9- and wait 10 seconds until the two symbols
Auxiliary heater -5- and Auxiliary ventilation -1- have stopped flashing. The auxiliary ventilation function is
activated the next time the ON/OFF button -8- is pressed.
Note
The auxiliary heater has 3 independent memory locations. Thus 3 different ON times can be programmed for
auxiliary heating or auxiliary ventilation.
The time at which heating or ventilation begins can be pre-set precisely to any time from one minute up to 24
hours.
The pre-selected ON time only remains effective for 24 hours.
Installation Location:
3. Select a memory location. To do this, press the memory location TIMER button -7- within 10 seconds after
adjusting auxiliary heating/ventilation.
4. Adjust the ON times. To do this, adjust the ON time using the + and - buttons. Pressing the buttons will
adjust the ON time by minutes. Holding down the button adjusts the time faster.
5. Save the ON time. To do this, press the ON/OFF button. The programmed ON time is displayed for approx.
2 minutes in the display.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Remove left front wheel . → 440519 Removing and installing wheel - chapter on "removing"
Remove front left wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"removing"
Installation Location:
Overview of complete heater
Note
Before disconnecting the water lines, it is essential to observe the safety
instructions in → 10 The most important working regulations and warning
information - Group 19 - Cooling !
4. Disconnect both lower hoses -c- and -d- with the hose clamp 3094.
8. Release spring band clamps using circlip pliers for spring band clamps, Cayenne hose connections
NR.72-1 -a- -arrows A- and slide them upwards off the flanges -arrow B- .
Releasing spring band clamps on Releasing spring band clamps
flanges
9. Pull out muffler downwards -arrow A- .
11. Pull out both lines together with the mount downward out of the
hoses -arrows B- .
Note
Before disconnecting the fuel line, it is essential to observe the safety
instructions in → 10 The most important working regulations and warning
information - Group 20 - Fuel supply, control!
14. Undo the clamp -arrow A- pull out the fuel line with the connecting
hose -arrow B- .
15. Unscrew the fastening nut -4- and the fastening screw -5- and undo the mount with the lines.
1. Engage the mount with the complete heating to the wheel housing
-arrow A- and screw down the fastening screws -arrows 6- . →
Tightening torque: 6 ftlb.
3. Place the mount with the lines onto the threaded pin -arrow- and screw down the fastening nut -4- and the
fastening screw -5- . → Tightening torque: 6 ftlb. → Tightening torque: 6 ftlb.
Note
Before connecting the water
hoses, apply suitable rubber
lubricant to the flanges.
Screwing down mount with lines onto Inserting the fuel line and tightening
threaded pin the clamp
4. Insert the lines into both hoses -arrows A- .
7. Slide the fastening clamp over the connection area -arrow C- and
screw down the fastening screw -arrow 1- .
8. Slide the spring band clamps with the circlip pliers for spring band
clamps, Cayenne hose connections NR.72-1 onto the connections
-arrow D- and align with the markings on the hose.
9. Relieve spring band clamps -arrows E- and secure the hoses.
11. Slide the spring band clamps with the circlip pliers for spring band
clamps, Cayenne hose connections NR.72-1 onto the connections
-arrow B- and align with the markings on the hose.
12. Relieve spring band clamps -arrows C- and secure the hoses.
14. Slide the spring band clamps with the circlip pliers for spring band clamps, Cayenne hose connections
NR.72-1 onto the connections -arrow B- and align with the markings on the hose.
15. Relieve spring band clamps -arrows C- and secure the hoses.
16. Unscrew the hose clamp 3094 and remove.
Connecting central plug Pushing hoses onto the lines
17. Push together plug connection -arrows A- until the locking tabs -arrows B- are felt to engage.
Subsequent work
Subsequent work
1. Fill in coolant and bleed cooling system. → 193817 Draining and filling coolant (includes bleeding)
2. Install front left wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
3. Installing front left wheel. → 440519 Removing and installing wheel - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Remove complete heater. → 822019 Removing and installing complete heater - chapter on "Removing"
Installation Location:
1. Unscrew fastening screw -Arrow 1- .
2. Open the fastening clamp -Arrow A- and unscrew the intake muffler
-Arrows B- .
2. Press the intake muffler upwards slightly -Arrow A- and detach the fastening clamp -Arrow B- .
3. Undo the fastening screw -Arrow 2- and take out the intake muffler with the clamp -Arrow- .
1. Insert the intake muffler in the intake manifold and tighten -Arrows- .
Unscrewing the fastening screw on the
intake manifold
2. Close the fastening clamp and tighten the fastening screw -Arrow 1- to the holder. → Tightening torque:
1.5 ftlb.
1. Push the intake muffler onto the flange on the heater -Arrow A- .
2. Engage the fastening clamp on the holder -Arrow B- and position the intake muffler in the installation
position -Arrow C- .
3. Secure the intake muffler on the holder with the fastening screw -Arrow 1- . → Tightening torque: 1.5 ftlb.
4. Secure the intake muffler with the fastening screw -Arrow 2- on heater.
Subsequent work
Subsequent work
Install complete heater. → 822019
Removing and installing complete
heater - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
Remove complete heater. → 822019 Removing and installing complete heater - chapter on "removing"
1. Mark the exact installation position of the line in the clips with
adhesive strips -arrows A- .
2. Open the clip -arrow B- , take the line out of the clip -arrow C- and
place aside to the rear.
11. Pull out the housing out of the inner hose -2- and take out to the
front.
1. Push on the outer connector -1- -arrow A- , until the locking tabs are felt to engage -arrow B- .
Plugging in connector
2. Push on inner connector -1- -arrow C- , until the locking tab -arrow D- is felt to engage.
Note
Before connecting the water hoses, apply suitable rubber lubricant to
the flanges.
4. Tightly screw the housing to the mount using the fastening screws
-arrows 3- . → Tightening torque: 1.5 ftlb.
10. Using circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 slide the spring band
clamp onto the connection -arrow B- .
11. Relieve spring band clamp -arrows C- and secure the hose.
Aligning the hose, connecting and
fastening the fuel line
12. Place the fuel line on the flange arrow -arrow D- and attach with a new clamp lug -b- .
Subsequent work
Subsequent work
Installing intake muffler with intake line. → 822119 Removing and installing intake muffler - chapter on "installing"
Install complete heater. → 822019 Removing and installing complete heater - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Note
The direction of travel is identified by an arrow with the designation x
Installation Location:
Overvew of fuel pump
Note
Before disconnecting the fuel line, it is essential to observe the safety
instructions in → 10 The most important working regulations and warning
information - Group 20 - Fuel supply, control!
.
3. Unscrew the fastening screw -arrow 1- and take out the fuel pump with the mount.
Note
When installing the fuel pump in the mount, make sure that the
electrical connection is in the lower installation position and points
forward.
1. Press in the fuel pump into the mount -arrow A- and centre it
-arrows B- .
4. Connect the plug -arrow A- until the locking tabs -arrows B- are felt to engage.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove exhaust system. → 260119 Removing and installing exhaust system - chapter on "removing"
2. Remove left catalytic converter. → 267319 Removing and installing (main) catalytic converter - chapter on
"removing" [9PAAD1 9PAAD7]→ 267319 Removing and installing (main) catalytic converter - chapter on
"removing" [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
3. Release centre bearing of cardan shaft. → 393519 Removing and installing rear cardan shaft - chapter on
"removing" [9PAAE1 9PAAE7 9PAAF1]→ 393519 Removing and installing rear cardan shaft - chapter on
"removing" [9PAAD1]→ 393519 21 Removing and installing rear cardan shaft - chapter on
"removing" [9PAAJ1]→ 393519 Removing and installing rear cardan shaft - chapter on "removing" [9PAAD7].
4. Remove cross member. → 390219 Removing and installing front cardan shaft - chapter on
"removing" [9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on
"removing" [9PAAD1 9PAAD7 9PAAE7]
5. Remove front left wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter
on "removing"
6. Remove underbody cover. → 519319 Removing and installing centre cover - chapter on "removing"
Installation Location:
Note
The direction of travel is identified by an arrow with the designation x
Note
Before disconnecting the fuel line, it is essential to observe the safety
instructions in → 10 The most important working regulations and warning
information - Group 20 - Fuel supply, control!
5. Release the clamp lugs -arrow A- on the fuel pump and on the
connection point in the wheel housing -arrow B- .
WARNING
Danger of injury due to falling components
Remove cover
2. Loosen the fastening screws -Arrow 4- - do not unscrew them
completely - and lower the tank on the right side arrow -arrow- .
4. Cut out the floor carpeting along the perforation and fold forward -Arrow A- .
5. Undo the fastening screws -Arrows 5- and take out the bracket with the seat-belt buckle -Arrow B- .
6. Unscrew the fastening nuts -Arrows 6- and remove the cover -Arrow C- .
Fold forward right rear seat
DANGER
Danger of fire and poisoning when working on fuel-carrying
components
7. Press in the locking mechanism -Arrow A- and pull off the fuel line
from the connection -Arrow B- .
Note
The direction of travel is shown by an arrow with the designation "x"
9. Release hose clamp -Arrow A- and pull off line from fuel pump
-Arrow B- .
Note
The direction of travel is shown by an arrow with the designation "x"
10. Unclip the line from the rear line holder -Arrow A- and pull down and
away from along the tank -Arrow B- .
11. Open the front holder -Arrow C- and remove line downward
-Arrow D- .
1. Release the clamp -Arrow A- and pull out the fuel line from the
housing -Arrow B- .
Note
Before installing the fuel line, apply a suitable rubber lubricant (tyre mounting paste) on the wheel housing
side of the rubber sleeve.
1. Slide the fuel line from below along the transmission -Arrows B- and guide it outward through the wheel
housing. If necessary, twist the fuel line slightly when installing it.
2. Press rubber sleeve into wheel housing -Arrow C- until it is felt to
engage in the body.
6. Close holder -Arrow B- until locking tabs are felt to engage -C- .
Note
The direction of travel is shown by an arrow with the designation "x"
1. Push the line through forwards -Arrow A- , connect to the fuel pump
-Arrow B- and fasten with a new hose clamp -C- .
2. Press line into holder and close the holder -Arrow D- until the locking
tab can be felt to engage.
3. Push the line through up along the tank -Arrow E- and press into
holder -Arrow F- until it can be felt to engage.
5. Press fuel line into the holder -Arrow C- until it is felt to engage.
6. Install cover -Arrow A- and screw down with the fastening nuts -Arrows 6- . → Tightening torque: 6.5 ftlb.
12. Fill the fuel line. → 825419 Removing and installing fuel line - chapter on "installing"
1. Push fuel line onto the adapter -Arrow A- and fasten with a new
clamp -Arrow B- .
2. Press fuel line into retaining clip -Arrows C- .
Note
The direction of travel is shown by an arrow with the designation "x"
Plugging in connector
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. >>
Continue.
3. Using the ?| key, move from the vehicle type to the control modules.
4. Select Auxiliary heater using the cursor keys and press the >> key.
5. Select Coding using the cursor keys and press the >> key.
6. Select Filling using the cursor keys and press the >> key. The fuel pump is activated for 50 seconds and fills
the fuel line.
Subsequent work
Subsequent work
1. Install cross member. → 390219 Removing and installing front cardan shaft - chapter on "installing" [9PAAE1
9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on "installing" [9PAAD1
9PAAD7 9PAAE7]
2. Fasten cardan shaft centre bearing support. → 393519 Removing and installing rear cardan shaft - chapter
on "installing" [9PAAE1 9PAAE7 9PAAF1]→ 393519 Removing and installing rear cardan shaft - chapter on
"installing" [9PAAD1] → 393519 23 Removing and installing rear cardan shaft - chapter on
"installing" [9PAAJ1]→ 393519 Removing and installing rear cardan shaft - chapter on "installing" [9PAAD7]
3. Install left catalytic converter. → 267319 Removing and installing (main) catalytic converter - chapter on
"installing" [9PAAD1 9PAAD7]→ 267319 Removing and installing (main) catalytic converter - chapter on
"installing" [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
4. Install exhaust system. → 260119 Removing and installing exhaust system - chapter on "installing"
5. Install underbody cover. → 519319 Removing and installing centre cover - chapter on "installing"
6. Install front left wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove left front wheel. → 440519 Removing and installing wheel - chapter on "removing"
2. Remove left front wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter
on "removing"
3. Remove left underbody cover. → 108019 Removing and installing engine guard - chapter on "removing"
Removing silencer
WARNING
Danger of burns on muffler
Installation Location:
Overview of muffler
Installing silencer
2. Tighten the mount with the fastening screws -arrow 1- . → Tightening torque: 6 ftlb.
3. Slide the clamp over the connection area -arrow- and screw down the fastening screw -arrow 2- .
Installing and screwing down mufflers Unscrewing fastening screws and
removing mufflers
Subsequent work
Subsequent work
1. Install left underbody cover. → 108019 Removing and installing engine guard - chapter on "installing"
2. Install left front wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
3. Install front wheel. → 440519 Removing and installing wheel - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Remove heater. → 822019 Removing and installing complete heater - chapter on "removing"
Installation Location:
Overview of exhaust pipe
1. Place the exhaust pipe on the flange -arrow A- and turn toward mount -arrow B- .
2. Screw down the exhaust pipe to mount using the fastening screw -2-
. → Tightening torque: 3.5 ftlb.
Subsequent work
Subsequent work
Install heater. → 822019 Removing and installing complete heater - chapter on "installing"
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Installation Location:
3. Undo the fastening screw -1- and remove the line holder -arrow B- .
Pulling off electric wire
4. Release the two spring band clamps using circlip pliers for spring band clamps, Cayenne hose
connections NR.72-1 ( -arrows A- ) and slide them off the connections -arrows B- .
5. Remove the line along with the hoses -arrow C- .
1. Release spring band clamp using circlip pliers for spring band
clamps, Cayenne hose connections NR.72-1 -arrows A- and slide
it off the flange -arrow B- .
1. Release spring band clamp using circlip pliers for spring band
clamps, Cayenne hose connections NR.72-1 -arrows A- and slide
it off the flange -arrow B- .
Removing line
3. Undo the fastening screw -arrow 1- and turn up the line holder
around the inner water line -arrow- .
Removing clamp
8. Release spring band clamp using circlip pliers for spring band
clamps, Cayenne hose connections NR.72-1 -arrows A- and slide
it off the flange -arrow B- .
9. Pull the circulation pump out of the hose -arrow C- .
Removing hose
1. Attach the two lines -a and b- to the threaded pin -arrow A- and
screw on the fastening nut -2- , but do not tighten.
Installing line
7. Connect the circulation pump to the hose -arrow A- and align at the
markings.
12. Connect the connector -arrow A- until the locking tab -arrow B- is felt to engage.
13. Push the moulded hose onto the line and the heater -arrows A- .
14. Use circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 to slide the spring band
clamps on to the connections -arrow B- and align with the marking on the hose.
15. Relieve spring band clamps -arrows C- and secure the moulded hose.
Inserting the connector
16. Turn the line holder back -arrow- and press on the outer line until it engages audibly.
17. Secure the line holder with the fastening screw -arrow 1- . → Tightening torque: 2.5 ftlb.
19. Use circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 to slide the spring band
clamp on to the connection -arrow B- and align with the marking on the hose.
20. Relieve spring band clamp -arrows C- and secure the hose.
2. Connect the line with the holder at the threaded pin and screw in the fastening nut -2- but do not tighten.
Installing line
Installing line to distribution valve and second heat exchanger
1. Attach the line to the distribution valve -a- and to the line to the second heat exchanger -b- ( -arrow A- ).
2. Use circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 to slide the spring band
clamps on to the connections -arrow B- and align with the markings.
3. Relieve the spring band clamps -arrows C- and secure the hoses.
4. Connect the line holder to both lines -arrow A- until the lines are felt to engage in the line holder.
5. Secure the line holder with the fastening screw -1- . → Tightening torque: 2.5 ftlb.
6. Connect the electric wire with the holder to the water line -arrow B- until the holder clicks into place.
Installing line holder Installing line
7. Clip in the fuel line -arrows- .
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove complete heater. → 822019 Removing and installing complete heater - chapter on "removing"
2. Remove intake muffler. → 822119 Removing and installing intake muffler - chapter on "removing"
1. Connect the check valve in the direction of flow -c- to the hose
-Arrow A- .
2. Align flow direction on check valve -c- with marking on hose -d- by
rotating the valve -Pfeile B- .
8. Slide the spring band clamps -1 und 2- with the circlip pliers for
spring band clamps, Cayenne hose connections NR.72-1 -a- onto
the flange -Arrow D- and align with the marking on the hose.
9. Relieve the spring band clamps -1 und 2- -Pfeile E- and secure the
hose.
Fastening the spring band clamps
Subsequent work
Subsequent work
1. Install intake muffler. → 822119 Removing and installing intake muffler - chapter on "installing"
2. Install complete heater. → 822019 Removing and installing complete heater - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
1. Remove complete heater. → 822019 Removing and installing complete heater - chapter on "removing"
2. Remove intake muffler. → 822119 Removing and installing intake muffler - chapter on "removing"
Removing directional-control valve
Installation Location:
6. Loosen spring band clamp -3- using circlip pliers for spring band
clamps, Cayenne hose connections NR.72-1 -Arrows A- and slide
it off the adapter -Arrow B- .
7. Remove hose from the directional-control valve -Arrow D- .
Note
Before installing the directional-control valve, apply a suitable rubber lubricant to all adapters.
To prevent the heater touching the body, align the water lines, hoses and spring band clamps accurately to
the markings before fastening them.→ 826919 Removing and installing pipes for additional heating
1. Push the directional-control valve onto the water hose -arrow- .
5. Slide spring band clamp -4- using circlip pliers for spring band
clamps, Cayenne hose connections NR.72-1 onto the connection
-Arrow A- and align with the marking on the hose.
6. Relieve the spring band clamp -4- -Arrows C- and secure the hose.
8. Slide spring band clamp -3- using circlip pliers for spring band
clamps, Cayenne hose connections NR.72-1 onto connection 2 of
directional-control valve -Arrow B- and align with the marking on the Fit front and lower hoses.
hose.
9. Relieve the spring band clamp -3- -Arrow C- and secure the hose.
10. Push upper hose onto connection 3 of directional-control valve -Arrow A- and align to marking.
11. Slide spring band clamp -2- using circlip pliers for spring band clamps, Cayenne hose connections
NR.72-1 onto connection 2 of directional-control valve -Arrow A- and align with the marking on the hose.
12. Relieve the spring band clamp -2- -Arrows B- and secure the hose.
14. Slide spring band clamp -1- using circlip pliers for spring band clamps, Cayenne hose connections
NR.72-1 onto connection 2 of directional-control valve -Arrow B- and align with the marking on the line.
Pushing hose onto the water line Fitting the hose
15. Relieve the spring band clamp -1- -Arrows C- and secure the hose.
16. Push on connector -Arrow A- until the locking tab -B- is felt to
engage.
Subsequent work
Subsequent work
1. Install intake muffler. → 822119 Removing and installing intake muffler - chapter on "installing"
2. Install complete heater. → 822019 Removing and installing complete heater - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Drain engine coolant. → 193817 Draining and topping up with coolant (includes bleeding) - chapter on
"draining"
2. Remove the carrier for the instrument panel. → 701219 Removing and installing carrier for instrument panel -
chapter on "Removing"
3. Remove the condenser-evaporator line and compressor-evaporator line at the expansion valve and close
the connections. → 877019 Removing and installing expansion valve - chapter on "Removing"
ATTENTION
Risk of material damage
→ Remove ignition key. Disconnect battery. Route or isolate the ground strap so that all contact with a ground
carrier (e.g. body, seat frame) is avoided. → 90 Work instructions after disconnecting the battery
Installation Location:
Overview of heater/air-conditioning unit
1. Support the heater/air-conditioning unit under the centre section -A- and under the evaporator -B- with a
plastic or wooden board.
3. Unscrew both fastening screws on the left heat exchanger cover and unclip the cover.
4. Unscrew the fastening screw of the right heat exchanger cover and unclip the cover.
5. Pull the retaining clips -arrows A- off the coolant supply line and return line.
Note
Unclipping wiring harness on the left
heat exchanger cover
9. Pull out centre air vents on the left -A- and right -B- .
10. Turn the left and right temperature sensor -90°- and pull out of the heater/air-conditioning unit.
11. Pull the centre air vents for the footwell downwards from the heater/air-conditioning unit, lift it toward the
rear, and pull it out of the air vents for the footwell.
12. Release the electric central connector -A- ( -arrows a- ), lever apart the connector lock -B- with two
screwdrivers and pull off.
Removing left and right air vents Releasing and removing centre air
guide
Note
Make sure not to damage the
insulation of the main wiring
harness.
Note
Before the heater/air-conditioning unit is installed again, the following points must be checked:
Check the water drainage hose for any cracks, deformities and other damage.
Check on the body for damage to both mounts (stars) for the heater/air-conditioning unit. The stars must be
able to turn for installation.
Water drainage hose
WARNING
Risk of damage to the mounts (stars)!
2. Slide the heater/air-conditioning unit onto both mounts (stars) and support it.
3. Push the water drainage hose onto the air-conditioning unit and
make sure it is seated correctly.
5. Lay the main wiring harness on the heater/air-conditioning unit and position it on the heater/air-conditioning
unit -A- and -B- using one tie-wrap each.
Engaging main wiring harness on
heater/air-conditioning unit
8. Insert the centre air vents for the footwell into the air guides for the
footwell and push onto the heater/air-conditioning unit.
10. Slide the lower centre air guide into the rear air guide -arrow B- , press the upper centre air guide onto the
Sliding lower centre air guide into rear Connecting centre air vents on the left
air guide and securing and right
heater/air-conditioning unit -arrow A- , and screw down with the two fastening screws -4- . → Tightening
torque: 1 ftlb.
11. Position the carrier for the instrument panel. → 701219 Removing and installing the carrier for the instrument
panel - chapter on "Installing"
12. Tighten the fastening screws -1- and -2- . → Tightening torque: 7.5 ftlb.
Note
Always replace O-rings.
14. Insert the coolant supply line and return line -B- into the heat
exchanger.
15. Push on the retaining clips -A- until the clips click into place.
18. Clip in left cover and secure with the fastening screws. → Tightening torque: 1 ftlb.
2. Carry out work instruction after disconnecting the battery. → 90 Work instructions after disconnecting the
battery.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Remove cover under dashboard right. → 702219 Removing and installing cover under dashboard - chapter on
"removing"
Installation Location:
Overview of particle filter insert
Remove cover
2. Pull out filter downwards.
Removing filter
1. Position filter from underneath and carefully push it into the air-
conditioning unit housing.
2. Engage cover -A- and screw in the fastening screws -arrows B- .
Subsequent work
Subsequent work
Install cover under dashboard right. → 702219 Removing and installing cover under dashboard - chapter on
"installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Remove cover under dashboard right. → 702219 Removing and installing cover under dashboard - chapter on
"removing"
Installation Location:
Overview of particle filter insert
Remove cover
2. Pull out filter downwards.
Removing filter
1. Position filter from underneath and carefully push it into the air-
conditioning unit housing.
2. Engage cover -A- and screw in the fastening screws -arrows B- .
Subsequent work
Subsequent work
Install cover under dashboard right. → 702219 Removing and installing cover under dashboard - chapter on
"installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove cover under dashboard right. → 702219 Removing and installing cover under dashboard - chapter
on "removing"
Installation Location:
Overview of heating and fresh air blower motor
3. Lift the electrical leads to one side and remove the fan downwards.
1. Lift the electrical leads to one side and push fan into housing from underneath.
2. Hold the fan, screw in the seven fastening screws -B- and screw down.
Removing fan
Installing fan
3. Insert the electrical plug connection -A- until the plug can be felt to engage.
4. Switch on ignition and the blower in stages on the heating and fresh-air control. Check the function of the
blower.
Subsequent work
Subsequent work
Install cover under dashboard right. → 702219 Removing and installing cover under dashboard - chapter on
"installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Note
Depending on vehicle equipment and on the required air guide, all interior components must be removed.
The removal and installation described provides information about routing and the connection or fastening
points.
The air guide auxiliary guide (rear four-zones) can be found under Removing and installing auxiliary air
conditioning air guide. → 883419 Removing and installing auxiliary air conditioning air guide
Installation Location:
Overview of air guide
2. First press the centre air guides downward, then pull to the rear in direction of travel and pull out of the lower
guides.
Unscrew the fastening nuts -2- and the pull apart the air guide.
2. Unscrew the fastening screws -1- for the air guide on the air conditioning unit and take out the air guide.
Insert the centre air guides into the lower air guides, press downward, and insert into the air conditioner. Insert the
side footwell outlet vents so they can be felt to engage.
Insert the centre air guides into the air conditioner. Insert the side footwell outlet vents so they can be felt to
engage.
Press the air guides together and screw down using the fastening nuts -2- . → Tightening torque: 1.5 ftlb.
2. Insert the centre console air guide and slide it into the air guide on the air conditioner.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
1. Carefully insert a plastic spatula at the four points between the air
vent and dashboard and prise out the air vent.
2. Press the electrical plug connection and pull off the plug.
2. Position air vent and press into the instrument panel until the air vent engages.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
1. Carefully insert a plastic spatula at the four points between the air
vent and dashboard and prise out the air vent.
2. Press the electrical plug connection and pull off the plug.
2. Position air vent and press into the instrument panel until the air vent engages.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
1. Open the doors and run a plastic spatula between the cover and
dashboard and remove the cover.
2. Unlock and disconnect the electrical plug connection.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove rear spoiler. → 635519 Removing and installing rear apron - chapter on "Removing"
3. Remove rear luggage compartment side-panel lining. → 700319 Removing and installing side-panel lining for
rear luggage compartment - chapter on "Removing"
Installation Location:
Overview of ventilation cover
Note
Simply push the styrofoam element aside when removing the right
ventilation cover.
1. Push in the ventilation cover -arrow A- until you feel the locking tabs
-arrows B- engage.
Subsequent work
Subsequent work
1. Install rear luggage compartment side-panel lining. → 700319 Removing and installing side-panel lining for
rear luggage compartment - chapter on "Installing"
2. Insert warning triangle (right side only).
3. Install rear spoiler. → 635519 Removing and installing rear apron - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Note
Close all openings immediately upon starting work on the refrigerant circuit.
When fitting parts, do not remove plugs until shortly before installation. Do not remove the protective foil from
the dryer until shortly before installation. The dryer absorbs moisture from the air and is then useless.
Replace the dryer after each occasion of working on the refrigerant circuit.
Moisture in the refrigerant circuit not only leads to poor cooling. Supersaturation can also cause the dryer to
disintegrate and contaminate the air-conditioning from inside. This may lead to expensive and complicated
repairs.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Technical values
Technical data
bar
High-pressure cut-off 32
Low-pressure cut-off 1
Pressure relief valve purge pressure 44 +/- 4
Tightening torques
Installation Location:
Overview of tightening torques
Note
When installing the refrigerant lines, the screw connections and the O-rings must always be wetted with
refrigerant oil!
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
WARNING
Danger of injury as a result of contact with liquid or gaseous refrigerants!
ATTENTION
Danger of fire due to the air-conditioning system heating up from sunlight shining into the vehicle or
during welding and soldering work!
→ When carrying out repairs on the air-conditioning system, the system must be emptied by suction and the
refrigerant must be purified. Chlorine-free refrigerants must also not be allowed to escape into the
atmosphere and must be disposed of correctly!
→ Due to their chemical composition, different refrigerants must not be mixed with each other! This also
applies for smaller quantities!
→
No welding, soldering or hot-air heating may take place on parts of the filled air-conditioning system or in its
immediate vicinity!
→ Make sure that parts of the air-conditioning system do not heat up during welding or brazing work on the
vehicle!
→ While drying after painting work, the temperature burden on the vehicle must not exceed two hours at a
maximum temperature of 80°C!
→ Whether or not the system is filled with refrigerant, the heating causes a very strong overpressure which can
cause damage to the system or even lead to an explosion!
→ R 134a is completely non-toxic at normal temperatures, but it decomposes upon contact with a flame or at
high temperatures!
→ Refrigerant bottles must not be thrown and must not be subjected to direct sunlight or other heat sources for
an extended period when full!
→ The maximum permissible temperature of a filled refrigerant bottle must not exceed 45 °C!
Safety measures
Note
The following safety measures should be followed for refrigerant R134a (additional regulations may apply in
certain countries).
If repair work necessitates opening the refrigerant circuit, the refrigerant circuit is first to be emptied. Avoid all
contact with liquid or gaseous refrigerants. If refrigerant should escape despite all safety measures having been
taken, the resulting refrigerant/air mixture should not be breathed in. Therefore, switch on extraction systems,
protect hands with rubber gloves and protect eyes with protective goggles.
ATTENTION
The intensive effect of refrigerant on unprotected body parts can cause freezing.
If refrigerant gets onto any other body parts despite all safety measures having been taken, these should also be
rinsed immediately and thoroughly with water for at least 15 minutes.
WARNING
Risk of injury!
→ High temperatures from open flames or hot solids causes chemical breakdown of refrigerant gas.
→ Inhalation of the resulting breakdown products leads to coughing and nausea.
Although refrigerant is non-flammable, smoking, welding, soldering and hard-soldering is prohibited in a room
containing refrigerant.
Refrigerant should not be released into the environment but is to be extracted from the refrigerant circuit using an
extraction or service station. The extracted refrigerant is then prepared again on-site or returned to the
manufacturer for environmentally-friendly disposal (varying or additional regulations may apply in certain
countries).
WARNING
Risk of injury!
→ The leaking refrigerant is not only colourless and odourless, but is also heavier than air and therefore
displaces oxygen.
→ If refrigerant gas escapes despite all safety measures having been taken, there is an undetectable risk of
suffocation in poorly ventilated rooms and erection pits.
→ The gas/air mixture formed when refrigerant escapes should not be breathed in but rather extracted via
suitable extraction systems (workshop extraction system).
→ No welding, soldering or hard-soldering should be carried out on any part of the filled air-conditioning
system.
→ This also applies to welding and soldering work on the vehicle when there is a danger of parts of the air-
conditioning system heating up.
→ The warming causes very strong overpressure in the system, which can cause the refrigerant system to
burst.
Work on the refrigerant circuit should only be carried out in areas with good ventilation. There should be no
erection pits, shafts or cellar stairs within a radius of 5 metres. Any extraction systems should be switched on.
ATTENTION
Possibility of material damage!
→ The warming causes very strong overpressure in the system, which can cause the refrigerant system to
burst.
When carrying out repairs involving painting work, object temperatures in the drying oven or its preheating zone
should not exceed 80 °C.
Information
The refrigerant circuit of the air-conditioning is only to be emptied and opened if this is necessary due to safety
measures or if components of the refrigerant circuit have to be replaced.
The air-conditioning refrigerant circuit also remains closed during all other standard vehicle repair work.
Contact corrosion
Note
For this reason, the manufacturer only fits connecting elements with a special surface coating.
Contact corrosion can occur if unsuitable connecting elements (screws, nuts, washers, rivets, plugs, grommets,
adhesives, etc.) are used.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
General information
Note
The air outlet temperatures at the centre nozzle of the dashboard and the high pressure in the air conditioner
must not exceed the specified tolerance ranges after an operating time of seven minutes.
Note
The safety regulations must be observed during all work on the refrigerant system! → , → ,
3. Open all air exhaust nozzles on the dashboard (if necessary direct the blower near the test person).
4. Insert sensor of the temperature measuring device approx. 4 cm centrally into the left-hand centre nozzle.
5. Check stopwatch and visual contact with the relevant temperature and pressure on the air conditioning
service unit.
6. Switch on ignition.
7. Open driver's and passenger's side windows and close sunroof.
8. Set the temperature for both sides to maximum cooling (LO appears in the display).
Note
With a 4-zone-air conditioner, the rear air conditioner must also be set to maximum cooling for both sides
(LO) (if necessary, use the MONO function) and the rear air exhaust nozzles left open. To activate the
MONO function, the AUTO -adjusting lever of the front air conditioning control must be pressed longer than
two seconds (MONO appears in the display).
10. Start engine and allow to run at idle speed (do not rev engine during or after starting!)
12. Bring engine speed up to 2000 rpm and maintain it there. Start the time measurement immediately.
13. Note centre nozzle temperature and pressure values after two minutes.
14. Compare values (centre nozzle temperature and pressure readings) with the specified tolerances.
Note
If the specified nominal values are not reached, the air conditioner must be checked for leaks and repaired!
Technical values
High pressure in refrigerant circuit as a function of outside temperature: 2-zone air conditioning
A - Upper limit
B - Lower limit
TA - Outside temperature (°C)
p - High pressure in refrigerant circuit (bar)
High pressure in refrigerant circuit as a function of outside temperature: 4-zone air conditioning
A - Upper limit
B - Lower limit
TA - Outside temperature (°C)
p - High pressure in refrigerant circuit (bar)
Tools and materials
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Note
Oil removed by suction must be returned to the system!
Refrigerant oil removed from a previously run air-conditioning system may no longer be used (special-
category waste)!
After the refrigerant has been removed by suction and a component has been replaced, the oil quantity must
be determined and topped up by the quantity remaining in the removed component!
When individual components listed in the following table are replaced, the measured oil quantity removed by
suction from the refrigerant circuit and the quantity in the component must be returned to the refrigerant circuit.
In order to use a new compressor in a refrigerant circuit that is already functional, the oil quantity of the new
compressor must be reduced by max. 80 cm3. The compressor oil quantity is 200 cm3 in the scope of delivery for
a new compressor.
Vehicle with 2+2: Distribution of oil quantity in the individual air-conditioning components
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Note
Before removing the air-conditioning system regulator, the selector lever must be pulled back for vehicles
with automatic transmission. Press the brake pedal for this purpose.
Installation Location:
Overview of front air-conditioning system regulator
1. Insert electrical plugs in the air-conditioning control until they are felt
to engage.
3. Fit the covering frame and press into place until it is felt to engage.
During coding, 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.
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. >>
Continue.
4. Select Air conditioning with the cursor keys and press the >> key.
5. Select Calibration with the cursor keys and press the >> key.
8. Select the corresponding equipment variant with the cursor keys and write coding with F8 .
10. Quit menu, switch off ignition, switch it back on, and read out fault memory once more.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
ATTENTION
Danger of injury when working on air-conditioned vehicles!
→ Observe safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a. → 80
Safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a
→ Observe safety regulations for working with extraction and filling systems. → 80 Safety regulations for
extraction and filling systems
→ Observe instructions for repairing air-conditioning systems and storing spare parts. → 80 Instructions for
repairing air-conditioning systems and storing spare parts
Note
The safety regulations must be observed during all work on the refrigerant system! → 80 Safety regulations
for working on air-conditioned vehicles and dealing with refrigerant R134a, → 80 Safety regulations for
extraction and filling systems.
During all work on the air-conditioning system which necessitates opening the refrigerant system, the system
contents must first be disposed of correctly!
Dirt and moisture must be kept out of the air-conditioning system's pipe system!
System components must never be cleaned on the inside with hot steam!
When replacing a component, all openings must be closed off with suitable plugs!
Note
Pay attention to sealing rings when disconnecting or connecting the
hose connections!
3.1. Let the engine run for a short while with the air-conditioning on, then connect the high-pressure and low-
pressure lines of the air-conditioning unit.
Note
In the case of service units with transparent oil separator, read and take note of the oil level before removing the
refrigerant.
Do not carry out this step with empty air-conditioning systems (pressure gauge approx. 0 bar), otherwise air will
get into the refrigerant bottle.
In the case of cold vehicles, it may be necessary to repeat the suction procedure until all refrigerant has been
removed from the air-conditioning system. This step is carried out automatically with some units.
4.1. Wait for approx. 2 minutes after the service unit has switched itself off. If the pressure gauge reading rises
above 0 bar, repeat the suction process.
Note
In the case of service units with transparent oil separator, read and take note of the oil level before removing the
refrigerant.
Do not carry out this step with empty air-conditioning systems (pressure gauge approx. 0 bar), otherwise air will
get into the refrigerant bottle.
In the case of cold vehicles, it may be necessary to repeat the suction procedure until all refrigerant has been
removed from the air-conditioning system. This step is carried out automatically with some units.
4.2. Drain the extracted refrigerant oil into a measuring cup on the service unit and determine the volume.
Note
The vehicle air-conditioning system is now completely empty. Necessary repairs, such as removing and
fitting the dryer, can now be carried out.
The open air-conditioning system should not be left open unnecessarily, but must be closed again as quickly
as possible after being opened.
If the air-conditioning system has been open for a long time, a new dryer must be fitted. → 875519 Removing
and installing dryer
6.1. Using the service unit, evacuate the system for 5-10 minutes.
6.2. Observe the pressure gauge for approx. 2 minutes. If the pressure rises, air is entering the vehicle air-
conditioning system. The leak must be located and repaired. If the pressure remains constant, add
refrigerant oil.
Note
Do not allow any air to be taken in, otherwise point 6 must be repeated.
7.2. Start the vacuum pump. At the start of this vacuum phase, add the measured quantity of refrigerant oil
using an oil injector or a hose disconnected from the service unit. Reconnect the hose to the service unit
immediately after adding the oil.
7.4. Add the measured quantity of refrigerant oil and wait for it to be taken in.
Note
If the air-conditioning system has been opened, evacuation should last at least 20 minutes so that the
moisture can evaporate and be removed by suction.
If the air-conditioning system has been open for a long time, evacuation can be carried out for up to 120
minutes.
8. Evacuate.
8.1. In the case of units with an integrated oil filling system, add refrigerant oil now.
ATTENTION
Low-pressure reading too high in refrigerant circuit.
Destruction of air-conditioning compressor.
→ Do not allow the low-pressure gauge to exceed 3 bar, otherwise liquid refrigerant can get onto the suction
side of the compressor and destroy it.
Note
As refrigerant usually flows instead of being pumped, it may not be possible - especially if the vehicle is warm
and the service unit cold - to add the entire quantity. If this is the case, switch the engine and the air-
conditioning on. Wait for the suction pressure to fall below 2 bar. Now open the low-pressure valve on the
unit slowly and carefully until the remaining quantity has been added.
9.1. Using the service unit, add the refrigerant quantity stated in the manual into the air-conditioning lines. → 80
Technical data for air-conditioning system
Note
The refrigerant in the high-pressure and low-pressure lines is part of the filling capacity of the refrigerant in
the air-conditioning system in the vehicle.
10. Add the refrigerant from both connection hoses to the air-conditioning system in the vehicle.
10.1. Close the valve on the high-pressure line and disconnect it from the vehicle.
10.2. Start the engine and air-conditioning system. When the pressure on both pressure gauges sinks below 2
bar, close the valve on the low-pressure line and disconnect it from the vehicle.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Overview
Removing sun sensor
1. Press sensor -B- into the holder until the sensor lugs engage.
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove trim under dashboard on left. → 701919 Removing and installing trim under dashboard -
"Removing" section
2. Remove KESSY/immobiliser control unit. → 966619 Removing and installing KESSY/immobiliser control unit
- "Removing" section
3. Remove vehicle electrical system control unit. → 971019 Removing and installing vehicle electrical system
control unit - chapter on "Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1] → 971019 21 Removing
and installing vehicle electrical system control unit - chapter on "Removing" [9PAAJ1]
4. Remove relay carrier. Remove relay carrier holder. → 9790 Relay carrier
Removing servomotor
Note
The air conditioner servo motor -B- - outer unit aimed at persons on left - is located on the left air
conditioning unit.
The air conditioner servo motor -C- - centre unit aimed at persons on left - is located on the left air
conditioning unit.
The individual servo motors -B und C- are not installed on both sides of the air conditioning unit in vehicles
with a manual air conditioner. These are replaced by just one air conditioner servo motor, which is installed
on the left side of the air conditioning unit at the servo motor position -B- .
Switch ignition off and remove ignition key before starting work.
Servo motors
1. Unscrew the fastening screws -arrows 1- of the retainer plate with
motors -D and E- .
5. Unscrew both fastening screws on the left heat exchanger cover and
unclip the cover.
Installing servomotor
1. Place the servo motor on the retainer plate and screw down using
the fastening screws -Arrows A- . → Tightening torque: 1.0 ftlb.
3. Move the servo motors with the Porsche System Tester to the service position. The drives must be parallel
to the guides -Z- .
Note
Switch on ignition and carry
out the service position menu,
Drive links menu with the
Porsche System Tester in the
Climatronic.
Note
Make sure that the drivers of the servo motors are pushed into the
mountings.
7. Insert retainer plate with the three servo motors from below into the
guides on the air conditioning unit as far as it will go.
12. Move the servo motors with the Porsche System Tester to the service position. The drives must be parallel
to the guides -Z- .
Servo motors in service position (2) Installing the cover and clipping in the
13. Push the electric plug connections onto the servo motors. wire harness
Note
Switch on ignition and carry out the service position menu, Drive links menu with the Porsche System Tester
in the Climatronic.
As an alternative, the servo motors can also be powered with 12 volts until they have reached the correct
position. Always use the circuit diagram for this.
Note
Make sure that the drivers of the servo motors are pushed into the
mountings.
16. Insert retainer plate with the two servo motors from below into the
guides on the air conditioning unit as far as it will go.
Subsequent work
1. Install relay carrier. Install relay carrier holder. → 9790 Relay carrier
2. Install vehicle electrical system control unit. → 971019 Removing and installing vehicle electrical system
control unit - "Installing" section [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1] → 971019 23 Removing and
installing vehicle electrical system control unit - "Installing" section [9PAAJ1]
3. Install KESSY/immobiliser control unit. → 966619 Removing and installing KESSY/immobiliser control unit -
"Installing" section.
4. Install trim under left dashboard. → 701919 Removing and installing trim under dashboard - "Installing"
section
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
2. Remove glove compartment. → 681519 Removing and installing glove compartment – section on
"Removing"
Removing servo motor for four-zone air conditioning
1. Unscrew the fastening screw on the right heat exchanger cover and
unclip the cover.
Note
In vehicles with four-zone air conditioning, four servo motors are
installed on the right-hand side of the air-conditioning system.
A - Servo motor for distributor flap for central vents at passenger’s side
B - Servo motor for distributor flap for side vents at passenger’s side
C - Servo motor for temperature mixing flap at passenger’s side
D - Servo motor for distributor flap for footwell outlet vent at passenger’s
side
2. Unscrew the fastening screws -1- on the lower retainer plate with the
motors.
3. Pull retainer plate with the motors downwards out of the guide.
1. Place the servo motor on the upper retainer plate and screw down using the fastening screws. → Tightening
torque: 1.5 (1.0 ftlb.) Nm
2. Connect electric plug connections to the servo motors until the connectors engage securely.
Note
Switch on ignition and carry out the service position menu, Drive links
menu with the Porsche System Tester in the Climatronic.
Note
Make sure that the drivers of the servo motors are pushed into the
mountings.
4. Insert upper retainer plate with the servo motors from below as far as
it will go into the guides on the air-conditioning unit.
Installation position
5. Tighten the two fastening screws -1- . → Tightening torque: 1.5 (1.0
ftlb.) Nm
Note
Switch on ignition and carry out the service position menu, Drive links
menu with the Porsche System Tester in the Climatronic.
Note
Make sure that the drivers of the servo motors are pushed into the
mountings.
10. Screw in both fastening screws -1- . → Tightening torque: 1.5 (1.0
ftlb.) Nm
11. Route electric lines at air-conditioning unit housing. When doing so,
make sure the lines are not pinched or damaged by the servo
motors.
Subsequent work
2. Install trim panel under dashboard at the right. → 701919 Removing and installing trim panel under
dashboard - section on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Partially detach the cowl panel cover. Loosen fastening screws and lift the cover. → 664419 Removing and
installing cowl panel cover - chapter on "removing"
Note
The air quality sensor is located in the direction of travel tucked under the cowl panel cover on the left side.
1. Lift cover -arrow A- , release the sensor -arrow B- and pull down from the mount - cowl panel cover
-arrow C- .
Plugging in connector
2. Push sensor onto mount - cowl panel cover - until the sensor clicks
into place. Check it is secure.
Subsequent work
Subsequent work
Position cowl panel cover and screw down with the fastening screws. → 664419 Removing and installing cowl
panel cover - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Draw off and dispose of refrigerant in the air-conditioning system in accordance with regulations. → 870317
Removing refrigerant by suction and filling
2. Remove left front wheel. → 440519 Removing and reinstalling wheel - chapter on "Removing"
3. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
4. Remove drive belt. → 137819 Removing and installing drive belt - chapter on "removing" [9PAAF1 9PAAJ1]
→ 137819 Removing and installing drive belt - chapter on "removing" [9PAAE1 9PAAE7]
WARNING
Danger of injury! Safety regulations should be strictly observed when working on air-conditioned
vehicles and dealing with refrigerant.
→ → 80 Safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a
→ → 80 Safety regulations for extraction and filling systems
→ → 80 Instructions for repairing air-conditioning systems and storing spare parts
Installation Location:
4. Remove the three fastening screws -3 and 4- from the air conditioning compressor.
5. Pull the steering hydraulic line to the front.
ATTENTION
Risk of damaging the air-conditioning compressor.
→ The engine must not be started until the air-conditioning system has been filled.
Note
If the air conditioning compressor is blocked/seized up, then additional steps must be carried out to ensure
the operation of the air conditioning. → 873419 Removing and installing air-conditioning compressor - chapter
on "Information"
Note
New compressors are pressurised and are filled with the required amount of oil for the refrigerant circuit!
The remaining oil quantity in the individual components must therefore be taken into account!
Refrigerant oil from the compressor or refrigerant oil removed by suction from a previously run air-
conditioning system may no longer be used (special-category waste)!
1. Open the cap on the high-pressure side and relieve the pressure from the compressor -A- .
4. Always replace the sealing ring for the oil filler screw. → Tightening
torque: 19 ftlb.
5. Use fastening screws from the new compressor. Replace O-rings
and wet the new rings with refrigerant oil.
8. Screw down the compressor and steering hydraulic line with the
fastening screws -3- → Tightening torque: 17 ftlb. and -4- →
Tightening torque: 34 ftlb. .
9. Do not remove the plugs for the lines and compressor connection -1-
and -2- until shortly before installation.
11. Push on connector -arrow B- , until lug -arrow a- clicks into place and insert into the support on the
compressor -arrow A- .
Remove desiccator from the condenser. → 875519 Removing and installing desiccator - chapter on
"Removing"
If there is wear/chips:
3. Remove the refrigerant line on the compressor - condenser. → 874319 Removing and installing compressor-
condenser line - chapter on "Removing"
5. Replace the condenser with desiccator. → 875019 Removing and installing condenser
6. Install the refrigerant line on the compressor-condenser. → 874319 Removing and installing compressor-
condenser line - chapter on "Installing"
If there is no wear/chips:
Subsequent work
Subsequent work
1. Install drive belt. → 137819 Removing and reinstalling drive belt - chapter on "Installing" [9PAAF1 9PAAJ1]
→ 137819 Removing and reinstalling drive belt - chapter on "Installing" [9PAAE1 9PAAE7].
2. Fill refrigerant on the air conditioner in accordance with regulations. → 870317 Removing refrigerant by
suction and filling
3. Open air exhaust nozzles on the dashboard, and set fan to at least 75 %.
4. After allowing the system to stabilise at idle speed (approx. 5 sec.), switch on air conditioner and allow the
engine to run uninterrupted for at least 2 minutes at 1500 rpm .
5. Switch off the air conditioner again. Do not drive until the air conditioner has been filled.
6. Install engine guard. → 108019 Removing and reinstalling engine guard - chapter on "Installing".
7. Mount left front wheel. → 440519 Removing and reinstalling wheel - chapter on "Installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
ATTENTION
Danger of injury from contact with the refrigerant
→ Observe safety regulations when working with refrigerant. → 80 Safety regulations for working on air-
conditioned vehicles and dealing with refrigerant R134a
Note
Removal and installation is described for a Turbo vehicle. There is additional hosing on the graphics which is
not installed on the naturally-aspirated engine.
Installation Location:
Overview of line on the compressor - condenser
1. Remove refrigerant by suction. → 870317 Adding refrigerant and removing by suction - chapter on "Draining"
5. Pull out the refrigerant line from the compressor and remove
downwards from the engine area.
1. Insert the refrigerant line from below into the engine area onto the air
conditioning compressor.
2. Screw in the fastening screw of the refrigerant line -A- on the
compressor and screw down. → Tightening torque: 9 ftlb.
Subsequent work
Subsequent work
1. Fill in refrigerant. → 870317 Evacuating and filling in refrigerant - chapter on "filling"
2. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
2. Drain coolant → 193817 Draining and topping up with coolant (includes bleeding) - chapter on "draining"
3.
Remove brake booster and the content required for this. → 477019 Removing and installing brake booster -
chapter on "removing"
4. Remove wiper motor. → 921519 Removing and installing wiper motor - chapter on "removing"
5. Remove cowl panel cover. → 664419 Removing and installing cowl panel cover - chapter on "removing"
2. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
3. Remove left front wheel. → 440519 Removing and installing wheel - chapter on "removing"
4. Remove front left wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter
on "removing"
5. Remove external power connection. → 974519 Installing and removing wiring harness for battery/external
power supply - chapter on "removing"
6. Remove left air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on
"removing" [9PAAF1 9PAAJ1]→ 242519 Removing and installing air cleaner housing - chapter on
"removing" [9PAAD1 9PAAD7]→ 242519 Removing and installing air cleaner housing - chapter on
"removing" [9PAAE1 9PAAE7]
Information
Note
Removal and installation is described for a Turbo vehicle. There is additional hosing on the graphics which is
not installed on the naturally-aspirated engine.
Overview of line on the condenser - evaporator
ATTENTION
Danger of injury from contact with the refrigerant
→ Observe safety regulations when working with refrigerant. → 80 Safety regulations for working on air-
conditioned vehicles and dealing with refrigerant R134a
Note
The condenser - evaporator line can only be removed together with the compressor - evaporator line.
→ 874519 Removing and installing compressor - evaporator line - chapter on "Removing"
Installation Location:
Overview of the (A - B) line on the condenser - evaporator
1. Remove refrigerant by suction. → 870317 Adding refrigerant and removing by suction - chapter on "Draining"
6. Unscrew fastening screws of both refrigerant lines and pull out the refrigerant line.
Unscrewing and removing the Unscrewing fastening nuts on the
fastening screws of the refrigerant fastening clamps
lines
7. Press the clips of the heating pipes together and push them down.
Mounting tools for spring-band clamps NR.72
8. Pull hoses off the lines.
ATTENTION
Danger of injury from contact with the refrigerant
→ Observe safety regulations when working with refrigerant. → 80 Safety regulations for working on air-
conditioned vehicles and dealing with refrigerant R134a
Note
The condenser - evaporator line can only be removed together with the compressor - evaporator line.
→ 874519 Removing and installing compressor - evaporator line - chapter on "Removing"
Installation Location:
1. Remove refrigerant by suction. → 870317 Adding refrigerant and removing by suction - chapter on "Draining"
6. Unscrew fastening screw for the mount of the refrigerant lines and
open the mount.
10. Lift the vehicle. Hold both refrigerant lines together, twist them, and
pull them downward through the left wheel housing opening.
Note
Always replace the sealing rings of the refrigerant lines.
The condenser - evaporator line can only be installed together with the compressor - evaporator line.
→ 874519 Removing and installing compressor - evaporator line - chapter on "Installing"
1. Insert refrigerant lines -A and B- into the radiator tank, position them,
and press them into the retaining clips.
4. Screw down the fastening nuts to the fastening clamps of both refrigerant lines. → Tightening torque: 6 ftlb.
5. Carefully place refrigerant lines onto expansion valve and press into place (do not tilt) and screw down using
the two fastening screws. → Tightening torque: 9 ftlb.
Screwing down fastening nuts on the Tightening fastening screws
fastening clamps
6. Push electrical plug onto
pressure switch until it clicks
into place.
Note
Always replace the sealing rings of the refrigerant lines.
The condenser - evaporator line can only be installed together with the compressor - evaporator line.
→ 874519 Removing and installing compressor - evaporator line - chapter on "Installing"
1. Lift the vehicle. Hold both refrigerant lines together, twist them, and insert them from below through the left
wheel housing opening.
2. Carefully clip in the connecting lines of the refrigerant lines into the
holder.
3. Attach the refrigerant lines in Clipping in connecting lines into the
the engine compartment to mounts
the connections (do not tilt)
and screw down using the
fastening screws -1- . →
Tightening torque: 9 ftlb.
10. Insert refrigerant line -B- into the condensor and screw it in using the fastening screw on the condenser. →
Tightening torque: 9 ftlb.
Subsequent work
2. Install brake booster and the content required for this. → 477019 Removing and installing brake booster -
chapter on "installing"
3. Install wiper motor. → 921519 Removing and installing wiper motor - chapter on "installing"
4. Install cowl panel cover. → 664419 Removing and installing cowl panel cover - chapter on "installing"
5. Refill coolant → 193817 Draining and refilling coolant (includes bleeding) - chapter on "refilling"
6. Install covers front left (engine compartment cover). → 700219 Removing and installing front cover (engine
compartment) - chapter on "installing"
2. Install left air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on
"installing" [9PAAF1 9PAAJ1]→ 242519 Removing and installing air cleaner housing - chapter on
"installing" [9PAAD1 9PAAD7]→ 242519 Removing and installing air cleaner housing - chapter on
"installing" [9PAAE1 9PAAE7]
3. Install front left wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
4. Fit left front wheel. → 440519 Removing and installing wheel - chapter on "installing"
5. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
7. Install covers front left (engine compartment cover). → 700219 Removing and installing front cover (engine
compartment) - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
2. Drain coolant → 193817 Draining and topping up with coolant (includes bleeding) - chapter on "draining"
3.
Remove brake booster and the content required for this. → 477019 Removing and installing brake booster -
chapter on "removing"
4. Remove wiper motor. → 921519 Removing and installing wiper motor - chapter on "removing"
5. Remove cowl panel cover. → 664419 Removing and installing cowl panel cover - chapter on "removing"
2. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
3. Remove left front wheel. → 440519 Removing and installing wheel - chapter on "removing"
4. Remove left front wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter
on "removing"
5. Remove external power connection. → 974519 Installing and removing wiring harness for battery/external
power supply - chapter on "removing"
6. Remove left air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on
"removing" [9PAAF1 9PAAJ1]→ 242519 Removing and installing air cleaner housing - chapter on
"removing" [9PAAD1 9PAAD7]→ 242519 Removing and installing air cleaner housing - chapter on
"removing" [9PAAE1 9PAAE7]
Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
Information
Note
Removal and installation is described for a Turbo vehicle. There is additional hosing on the graphics which is
not installed on the naturally-aspirated engine.
Overview of line on the compressor - evaporator
ATTENTION
Danger of injury from contact with the refrigerant
→ Observe safety regulations when working with refrigerant. → 80 Safety regulations for working on air-
conditioned vehicles and dealing with refrigerant R134a
Note
The compressor - evaporator line can only be removed together with the condenser - evaporator line.
→ 874419 Removing and installing condenser - evaporator line - chapter on "Removing"
Installation Location:
Overview of the (A - B) line on the compressor - evaporator
1. Remove refrigerant by suction. → 870317 Adding refrigerant and removing by suction - chapter on "Draining"
6. Unscrew fastening screws of both refrigerant lines and pull out the refrigerant line.
Unscrewing and removing the Unscrewing fastening nuts on the
fastening screws of the refrigerant fastening clamps
lines
7. Press the clips of the heating pipes together and push them down.
Mounting tools for spring-band clamps NR.72
8. Pull hoses off the lines.
ATTENTION
Danger of injury from contact with the refrigerant
→ Observe safety regulations when working with refrigerant. → 80 Safety regulations for working on air-
conditioned vehicles and dealing with refrigerant R134a
Note
The compressor - evaporator line can only be removed together with the condenser - evaporator line.
→ 874419 Removing and installing condenser - evaporator line - chapter on "Removing"
Installation Location:
1. Remove refrigerant by suction. → 870317 Adding refrigerant and removing by suction - chapter on "Draining"
6. Unscrew fastening screw for the mount of the refrigerant lines and
open the mount.
10. Lift the vehicle. Hold both refrigerant lines together, twist them, and
pull them downward through the left wheel housing opening.
ATTENTION
Danger of injury from contact with the refrigerant
→ Observe safety regulations when working with refrigerant. → 80 Safety regulations for working on air-
conditioned vehicles and dealing with refrigerant R134a
Installation Location:
1. Remove refrigerant by suction. → 870317 Adding refrigerant and removing by suction - chapter on "Draining"
5. Pull out the refrigerant line from the compressor and remove downwards from the engine area.
Note
Always replace the sealing rings of the refrigerant lines.
The compressor - evaporator line can only be installed together with the condenser - evaporator line.
→ 874419 Removing and installing condenser - evaporator line - chapter on "Installing"
1. Insert refrigerant lines in the radiator tank, position them, and clip
them into the retaining clips.
3. Attach the refrigerant lines in the engine compartment to the connections (do not tilt) and screw down using
the fastening screws -1- . → Tightening torque: 9 ftlb.
Tightening fastening screws Connecting and securing hoses for
heating
4. Screw down the fastening nuts to the fastening clamps of both refrigerant lines. → Tightening torque: 6 ftlb.
5. Carefully place refrigerant lines onto expansion valve and press into
place (do not tilt) and screw down using the two fastening screws. →
Tightening torque: 9 ftlb.
Note
Always replace the sealing rings of the refrigerant lines.
The compressor - evaporator line can only be installed together with the condenser - evaporator line.
→ 874419 Removing and installing condenser - evaporator line - chapter on "Installing"
Installation Location:
1. Lift the vehicle. Hold both refrigerant lines together, twist them, and insert them from below through the left
wheel housing opening.
2. Carefully clip in the connecting lines of the refrigerant lines into the
holder.
6. Place the three fastening clamps onto the threaded pins and screw down using the three fastening nuts -3- .
→ Tightening torque: 6 ftlb.
Note
Always replace the sealing rings of the refrigerant lines.
Spray the sealing rings with refrigerant oil before fitting.
1. Insert the refrigerant line from below into the engine area onto the air
conditioning compressor.
2. Install brake booster and the content required for this. → 477019 Removing and installing brake booster -
chapter on "installing"
3. Install wiper motor. → 921519 Removing and installing wiper motor - chapter on "installing"
4. Install cowl panel cover. → 664419 Removing and installing cowl panel cover - chapter on "installing"
5. Refill coolant → 193817 Draining and refilling coolant (includes bleeding) - chapter on "refilling"
6. Install covers front left (engine compartment cover). → 700219 Removing and installing front cover (engine
compartment) - chapter on "installing"
2. Install left air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on
"installing" [9PAAF1 9PAAJ1]→ 242519 Removing and installing air cleaner housing - chapter on
"installing" [9PAAD1 9PAAD7]→ 242519 Removing and installing air cleaner housing - chapter on
"installing" [9PAAE1 9PAAE7]
3. Install left front wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
4. Fit left front wheel. → 440519 Removing and installing wheel - chapter on "installing"
5. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
7. Install covers front left (engine compartment cover). → 700219 Removing and installing front cover (engine
compartment) - chapter on "installing"
2. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
1. Remove refrigerant by suction. → 870317 Evacuating and filling in refrigerant - chapter on "draining"
2. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
3. Remove lock carrier. → 503809 Detaching and fastening lock carrier (service position) - chapter on
"detaching".
WARNING
Danger of injury! Safety regulations must be strictly observed when working on air-conditioned vehicles
and dealing with refrigerant.
→ → 80 Safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a
→ → 80 Safety regulations for extraction and filling systems
→ → 80 Instructions for repairing air-conditioning systems and storing spare parts
Installation Location:
Overview of condenser
1. Remove the support plate under the radiator. To do this, loosen the
four fastening screws.
2. Unscrew the fastening screws -A and B- for the air-conditioning lines to the condenser, remove the lines and
close them off so that they are air-tight.
6. Detach power steering radiator from condenser -Arrow A- and remove from the support -Arrow B- .
7. Carefully pull the ATF cooler -3- to the front, making sure that the lines do not become deformed.
1 - Coolant radiator
2 - Condenser
Detaching power steering radiator.
3 - ATF cooler
4 - Power steering radiator
Note
Fix the remaining radiators in the installation position using tie wraps.
8. Carefully pull the condenser -2- upwards and out, making sure not to damage the other radiators with the
edges and corners of the condenser.
1. Carefully pull the ATF radiator -3- to the front, making sure that the lines do not become deformed.
1 - Coolant radiator
2 - Condenser
3 - ATF cooler
4 - Power steering radiator
2. Carefully insert the condenser -2- between the radiators -1, 3, 4- , making sure not to damage the other
radiator on the edges and corners of the condenser.
Locks on ATF cooler and condenser Pulling ATF radiator forwards and
removing condenser upwards
3. Engage the condenser and the ATF cooler in the mounts and clip in both retaining clips on the condenser
and on the coolant radiator.
7. Position the refrigerant lines and attach them to the condenser with the fastening screws -A and B- . →
Tightening fastening screws for air- Screwing in fastening screws for
conditioning lines to condenser securing condenser to coolant radiator
Tightening torque: 9 ftlb.
Subsequent work
Subsequent work
1. Fill in refrigerant. → 870317 Evacuating and filling in refrigerant - chapter on "filling"
2. Install lock carrier. → 503819 Removing and installing lock carrier - chapter on "installing".
3. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing".
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Preliminary work
Preliminary work
Remove radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) - chapter on
"removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 21 Removing and installing cooling fan
housing (radiator frame) - chapter on "removing" [9PAAJ1]
Note
The big fan is for the engine cooling, the small fan is for the air conditioning
The sheetmetal clips on the fans are for balancing the fans and must not be pulled off.
Installation Location:
Overview of fan for condenser
3. Follow up the fan cable and fan control module during removal.
Subsequent work
Subsequent work
Install radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) - chapter on
"installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and installing cooling fan
housing (radiator frame) - chapter on "installing" [9PAAJ1]
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Tools
Preliminary work
Preliminary work
Remove refrigerant by suction. → 870317 Evacuating and filling in refrigerant - chapter on "draining"
Removing desiccator
WARNING
Danger of injury! Safety regulations should be strictly observed when working on air-conditioned
vehicles and dealing with refrigerant.
→ → 80 Safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a
→ → 80 Safety regulations for extraction and filling systems
→ → 80 Instructions for repairing air-conditioning systems and storing spare parts
Note
The dryer is in the capacitor, on the right-hand side.
1. Remove air filter lid. → 242519 Removing and installing air cleaner
housing - chapter on "Removing" [9PAAF1 9PAAJ1]→ 242519
Removing and installing air cleaner housing - chapter on
"Removing" [9PAAD1 9PAAD7]→ 242519 Removing and installing air
cleaner housing - chapter on "Removing" [9PAAE1 9PAAE7].
Installing desiccator
Note
The dryer must be replaced if the system suffers from operational faults (e.g. accident damage or air-
conditioning system depressurised)!
Used refrigerant oil extracted from a previously run A/C unit must not be re-used!
1. Replace O-ring on plug and wet with refrigerant oil.
6. Install air filter lid. → 242519 Removing and installing air cleaner
housing - chapter on "Installing" [9PAAF1 9PAAJ1]→ 242519
Removing and installing air cleaner housing - chapter on
"Installing" [9PAAD1 9PAAD7]→ 242519 Removing and installing air
cleaner housing - chapter on "Installing" [9PAAE1 9PAAE7]
7. Determine the quantity of the refrigerant oil and fill up again with
refrigerant oil (volume removed by suction + 20 cm 3).
Subsequent work
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
Information
Note
Vehicles with manual air conditioner only have the evaporator temperature sensor -1- installed.
Before removing the temperature sensors/interior temperature sensors, switch off the ignition and remove
the ignition key.
Positions of the air conditioning unit temperature sensor
Preliminary work
Remove glove compartment. → 681519 Removing and installing glove compartment - chapter on "removing"
Remove the cover from under the right dashboard. → 702219 Removing and reinstalling cover under dashboard -
chapter on "Removing"
Remove glove compartment. → 681519 Removing and installing glove compartment - chapter on "removing"
Removing servomotor for air conditioner. → 872019 Removing and reinstalling servo motor - chapter on
"Removing"
Preliminary work for temperature sensor for footwell outlet vent, left side
Remove servomotor. → 872019 Removing and reinstalling servo motor - chapter on "Removing"
Preliminary work for temperature sensor for footwell outlet vent, right side
Remove glove compartment. → 681519 Removing and installing glove compartment - chapter on "removing"
2. Press latch on the electric connector for the sensor -1- -arrows a-
and pull off the connector.
2. Press latch on the electric connector for the sensor -2- -arrows a-
and pull off the connector.
2. Press latch on the electric connector for the sensor -arrow a- and pull off the connector.
2. Turn temperature sensor -5- 90° and remove from the heater/air-
conditioning unit.
2. Press latch on connector -arrows a- and pull off connector from the temperature sensor.
2. Slide in the temperature sensor -2- into the heating/air-conditioning unit and turn 90°.
2. Insert the electric connector into the sensor -4- until the connector is
felt to engage.
2. Insert the electric connector into the sensor -5- until the connector is
felt to engage.
2. Slide in the temperature sensor into the heater and turn 90°. Ensure it is seated properly.
Subsequent work
Install glove compartment. → 681519 Removing and installing glove compartment - chapter on "installing"
Install the cover under the right dashboard. → 702219 Removing and reinstalling cover under dashboard - chapter
on "Installing"
Install glove compartment. → 681519 Removing and installing glove compartment - chapter on "installing"
Installing the servomotor for air conditioning. → 872019 Removing and reinstalling servo motor - chapter on
"Installing"
Install servomotor. → 872019 Removing and reinstalling servo motor - chapter on "Installing"
9P