Tires/Wheels - Spare Tire Carrier Installation/Service
Cayenne4/04 4456
Binder - 4, Running Gear
Spare Wheel Carrier Installation Instructions (I No. 1G3)
Date: 8-11-04
Vehicle Type:
Cayenne/Cayenne S/Cayenne Turbo
Model Year:
As of '03 (3)
Concern:
Retrofitting
Information:
A spare wheel carrier (Figure 001) can be retrofitted to the above vehicles. This pivoting spare wheel carrier will hold any of the wheels offered in the Cayenne line-up, except for the size 10J x 20" SportTechno wheel.
The rear hatch window can still be opened when the spare wheel carrier (with the wheel) is closed. Various parts need to be ordered separately, depending on the vehicle equipment, e.g. with/without trailer hitch or with/without ParkAssist etc. (see parts to be ordered separately).
The spare wheel carrier is also available factory installed option when ordering a new vehicles under the I No. "1G3".
Parts Information:
Parts List
Depending on the vehicle equipment, the following parts must be ordered separately:
Information:
Additional parts such as the spare wheel and tire that will be held on the carrier, the corresponding wheel bolts and the spare wheel securing bolt have to be ordered separately according to PET (Porsche Electronic Parts catalog).
Caution!
Danger of injury and damage to property - in the event of improper operation of the spare wheel carrier.
> Make sure that no persons or pets are in the swinging range of the spare wheel carrier.
> If the vehicle is on a lateral slope, the additional locking mechanism for the spare wheel carrier must be operated.
> The emergency release for the spare wheel carrier may only be operated if the vehicle is on level ground.
> Observe instructions on this subject in the Cayenne Owners Manual.
Material:
Tools:
Work Procedure:
1. Preparatory work.
1.1 Paint new rear apron, cover for the rear lid and, in the case of the Cayenne Turbo, the bottom part of the rear apron in accordance with the vehicle color code as per the Paint Manual.
1.2 Remove rear apron (Technical Manual, Group 6, Part ID. 6355).
1.3 Remove rear bumper, referred to as cross member below or trailer hitch (Azv) (Technical Manual, Group 6, Part ID. 6350 or Part ID. 6690).
1.4 Remove right side-panel lining in luggage compartment (Technical Manual, Group 6, Part ID. 7003).
1.5 Remove trim on D-pillar (Technical Manual, Group 6, Part ID. 7069).
1.6 Remove CD changer with holder (Technical Manual, Group 9, Part ID 6160) and rear control module (CM) incl. holder on right-hand panel.
1.7 Only vehicles with 4-zone air conditioning system (auxiliary air-conditioning unit):
1.7.1 Remove left side-panel lining in luggage compartment (Technical Manual, Group 6, Part ID. 7003).
1.7.2 Release auxiliary air-conditioning unit on the rear left and panel (Technical Manual, Group 8, Part ID. 8810).
1.7.3 Without kinking the lines, carefully fold the auxiliary air-conditioning unit to one side and secure in the vehicle.
2. Mounting the new trailer hitch or new cross member on the vehicle.
2.1 Preparatory work.
2.1.1 Check whether the 4 x pop rivet nuts M6 (spare wheel carrier lock assembly) are present on the new cross member (Figure 003, A) or on the new trailer hitch (inset B) at Item C.
2.1.2 Insert the 4 pop rivet nuts M6 / 3.56 on the respective carrier with the pop rivet hand tool (see also Technical Manual, Group 6, Part ID. 6350).
2.1.3 Carefully and without damaging it, remove the foam part from the trailer hitch (existing or new) or cross member.
2.1.4 Shorten the foam part along the cutting line X-X on the right-hand side (see underside of foam part; Figure 004, Item A) (Technical Manual, Group 6, Part ID. 6690).
2.1.5 Stick on several strips of double-sided adhesive tape or butyl sealing cord to the underside of the foam part (Item B).
2.1.6 Align the foam part on the upper side of the new cross member or trailer hitch and stick on.
2.1.7 Clip 2 x plastic clips onto the new cross member or trailer hitch on the left-hand side (Figure 005, Item A).
2.1.8 Mount lock (md. bowden cable) with 4 x hexagon-head bolts M6 x 25 on the new cross member or on the trailer hitch (Item B).
Tightening torque: 10 Nm (7.5 ftlb.)
2.1.9 Route the Bowden cable (emergency release lock) to the plastic clips in the rear channel of the foam part and secure in the clips.
2.2 Only vehicles with trailer hitch:
2.2.1 Position 8 new sealing rings (Item A) on the new trailer hitch.
2.2.2 Mount new trailer hitch (Item B) to rear of vehicle
with 8 new screws M14 x 1.5 x 100 (Item C)
(Technical Manual, Group 6, Part ID. 6690).
Tightening torque: 100 Nm (74 ftlb.) + 90°C
2.3 Only vehicles with cross member:
Mount new cross member to rear of vehicle with 8 new screws M14 x 1.5 x 45 (Technical Manual, Group 6, Part ID. 6350).
Tightening torque: 150 + 30 Nm (111 + 22 ftlb.)
3. Installing spare wheel carrier.
3.1 Top bracket.
Note:
To prevent water entering into the ~pilIar1 the bracket on the installed spare wheel carrier must be installed properly to ensure no water enters vehicle. Make sure that the bracket is flush with the sheetmetal of the D-pillar during installation (see Step 3.1.3).
3.1.1 Insert the bracket by turning it into the cavity on the left-hand D-pillar (Items A to C).
3.1.2 Tighten the mount hand tight in the pillar (Item D) with 4 x hexagon-head bolts M8 x 16 (10.9).
Note:
The other three bolts must be tightened before the top, left-hand bolt can be turned.
3.1.3 Stick adhesive tape onto the contact surface of 3 washers 10 (see required material) to protect the paint.
3.1.4 Fasten the bracket to the D-pillar (Item E) using 3 x pan head screws M8 x 16 and 3 x washers 10.
3.1.5 Screw bracket tightly into the pillar using 4 x hexagon-head bolts M8 x 16 (10.9).
Tightening torque: 33 (24) +/- 3,3 (2.5) Nm (ftlb.).
3.1.6 Remove 3 x pan head screws M8 x 16 and 3 x washers (these are no longer required).
3.2 Bottom bracket.
3.2.1 Remove 4 x plastic plugs M8 from the threaded bushings (Item A, arrow indicates direction of travel).
3.2.2 Position lower mount in front of the 4 threaded bushings and tighten by hand using 4 x hexagon-head bolts M8 x 25 (Item B).
3.3 Test fit and adjust the spare wheel carrier.
Reason:
- checking and adjusting the latch striker from the spare wheel carrier to the lock;
- checking degree of movement of the upper support (Item A) in the mount (Item B). The latter must not drag in area C when opening or closing the spare wheel carrier!
3.3.1 Two persons should place the spare wheel carrier on the brackets and loosely pre-fit with the following screws:
- top bracket: 3 x Torx flange screw; M8 x 30 (Figure 009, top);
- bottom bracket: pre-fitted 2 x threaded plug M16 x 25 (Figure 009, bottom).
3.3.2 Mount the spare wheel.
3.3.3 Open and close the spare wheel carrier; if necessary, adjust lower left mount as well as the latch striker (Figure 010) according to the criteria under Step 3.3.
3.3.4 Tighten bottom bracket to vehicle body (see Figure 008).
Tightening torque: 33 (24) +/- 3,3 (2.5) Nm (ftlb.).
3.3.5 Tighten latch striker to spare wheel carrier (see Figure 008).
Tightening torque: 33 (24) +/- 3,3 (2.5) Nm (ftlb.).
3.3.6 Remove spare wheel carrier again.
4. Routing and connecting electrical wiring harnesses.
4.1. Interior electrical wiring harness.
4.1.1 Route electrical wiring harness as follows:
-> Relay socket (Item A)
-> Ground point MB40 (Item B) -> dummy plug Floor pan; area of right D-pillar (Item C)
-> Along rear closing panel up to left D-pillar (Item D).
4.1.2 Ring eyelet of BN wire; 1.5 sq. attach to ground point MB40 (Item B).
4.1.3 Record positions of the wires in the 4-pole connector (license plate light and decrimp wires.
4.1.4 Feed wires through the hole in the floorpan (right D-pillar; Item C in inset of Figure 011) to the outside.
4.1.5 Reconnect wires in former positions in connector housing and attach grommet.
4.1.6 Decrimp old wires of license plate light from connector A (black, 23-pole); pin 9 of the "rear comfort systems" control module (CM) and tie back, as this connector is now obsolete.
4.1.7 Connect electrical wiring harness on the connectors A (black; 23-pole) and C (brown; 2-pole) and for the "rear comfort systems" control module as follows:
4.1.8 Install rear control module and plug in connectors A/B/C.
4.1.9 Insert relay on left of rear CM to the underside of the holder.
4.2 Exterior electrical wiring harness.
4.2.1 Feed 10-pole connector through the empty hole (area of rear left wheel well; inset in Figure 013) into the passenger compartment from outside.
4.2.2 Establish plug connection to interior electrical wiring harness and attach grommet.
4.2.3 Push 1 x cable clip onto the upper welded pin of the vehicle.
4.2A Secure electrical wires to the lower mount in positions A-D using further clips.
4.2.5 Establishing electrical plug connections:
- 3-pole connector -> limit switch;
- 2-pole connector -> handle button.
4.2.6 Route the remaining wires through the foam part to the lock of the spare wheel carrier and establish plug connections.
Note:
The plug connections are coded and cannot be interchanged.
5. Converting the rear of the rear hatch (rear lid).
5.1 Open rear window and carefully unclip the trim for the rear lid using a plastic spatula (Part ID 6647).
5.2 Stick spacers (5 each) to the newly painted trim.
5.3 Stick new trim strip to the newly painted trim paying attention to the seam joining line.
5.4 Clip the new trim onto the rear lid.
6. Completing the new rear apron.
6.1 Cut out rear apron for trailer hitch according version (see markings on the inside) as follows:
A - trailer hitch without hook/ball head (USA only);
B - trailer hitch with el. folding ball head (RoW);
C - trailer hitch with detachable ball head (RoW).
6.2 Combine top and bottom part of rear apron (Part ID 6355).
6.3 Clip new stainless steel cover onto the top side of the rear apron.
6.4 Route electrical wiring harness through rear apron and secure it with the 4 x cable clips in the rear apron.
6.5 Attach silver cover to bottom bracket of spare wheel holder.
6.6 Establish plug connection to wiring harness on vehicle side and install rear apron on vehicle.
7. Installing the spare wheel carrier (final).
7.1 Establish plug connections to spare wheel carrier and fit spare wheel carrier.
7.2 Tighten spare wheel carrier to the brackets (see Figure 009).
Tightening torque for top:
33 (24) +/- 3,3 (2.5) Nm (ftlb.).
Tightening torque for bottom:
70 (52) +/- 3,5 (2.5) Nm (ftlb.).
8. Concluding work.
8.1 Activate the spare wheel carrier and carry out a function text with the PST2.
8.1.1 Activate the spare wheel carrier with the PST2.
8.1.2 Connect PST2; select the vehicle and read out CM.
8.1.3 Read out fault memory.
8.1.4 Select "Rear doors" menu item:
-> Erase fault memory; -> select Coding.
8.1.5 Menu item. Select "external spare wheel":
-> when coding: "Function interrupted due to error" must be set to "not installed";
-> select "installed" and code with F8
8.2 Function test after successful coding.
8.2.1 Pull handle on spare wheel carrier: the servo motor in the lock assembly must operate audibly.
8.2.2 When the spare wheel carrier is open, the center display of the instrument cluster must show the vehicle with the spare wheel carrier open.
8.2.3 Close the rear lid and then the spare wheel carrier. The display in the instrument cluster must disappear.
8.2.4 Unlock spare wheel carrier and open it only halfway. In this position, try to open the rear lid. It must not be possible to open it because the spare wheel carrier has not yet reached its end position.
Working Time:
References:
Disclaimer