Campaign - Headlamp Modification for Condensation
Cayenne10/04 W424
Date: 9-24-04
Binder - 9, Electrical System
W424 - Modifying Ventilation of Main Headlights
(Workshop Service Action)
Vehicle Type:
Cayenne/Cayenne S/Cayenne Turbo
Model Year:
M.Y. 2003 (3) / M.Y. 2004 (4) / M.Y. 2005 (5)
Concern:
Converting main headlight ventilation.
Information:
This is to inform you of a voluntary Workshop Service Action on certain 2003, 2004 and 2005 model year Cayenne (V6), Cayenne S and Cayenne Turbo vehicles. Due to improper ventilation, there is the possibility that the cover lens of both main headlights could fog on the inside.
To remedy the situation, a conversion must be made to the ventilation of both headlights.
We ask that the aforementioned procedure be performed on the affected vehicles listed below during the Porsche Owner's next visit to your workshop.
Affected Vehicles:
A total of 28,697 U.S. and 1,612 Canadian vehicles fall within the scope of this Service Action.
Very Important!
Not every vehicle in the below listed range may be affected. Use the ranges below as a general guideline. Alternatively, the VIN can be checked in the Porsche e-DCS/WWS for confirmation of an open service action.
The affected Vehicle Identification Numbers are contained in the VIN Ranges shown.
Work Procedure:
See Attachment "A"
Time Allowance:
Parts Required:
Tools:
Flat screwdriver (medium)
Flat screwdriver (small)
Hot air gun
Attachment "A" Work Procedure:
Replace cap of main headlight and cap for the auxiliary high beam headlight.
Caution!
Risk of short circuit. Damage (scratching) of main headlight.
> Before removing headlight, remove ignition key and switch off light switch.
> Perform assembly work with the headlight on a soft surface in order prevent scratching the headlight.
1. Switch lights and ignition "Off".
2. Remove both main headlights according to the Technical Manual, Group 9, Chapter 94 15 19.
3. Place both main headlights on a soft surface for the conversion work.
4. Open both locking bars from the caps of the right and left main headlight (Figure 1, Item 1), take off caps.
5. Pull off the cap for the auxiliary high beam headlight (Figure 1, Item 2) to the rear on the right and left main headlight.
6. If one or both main headlights are fogging:
Yes - continue with Step 7. No - continue with Step 8.
Caution!
Damage to the main headlight from the heating effect of the hot-air gun.
> Pay attention to the air outlet direction of the hot-air gun to avoid damage to the housing.
> Damage as a result of extreme heating.
7. Dry the main headlights using a hot air gun by alternating the heating of the light-diffusing lenses from the outside and inside. To dry on the inside, blow the warm air in alternation through the rear openings on the main headlight (Figure 2, Item 1 and Item 2).
Note:
The temperature of the hot air gun must not be higher than 158° F. (70° C).
8. Fit the cap for the auxiliary high beam headlight on the right and left main headlights (Figure 3, Item 2), part number, 955.631.233.10 50 that the ventilation inlet points downward and make sure the cap is seated securely.
Note:
Do not use sliding agents/lubricants.
9. Place a new main headlight cap (Figure 3, Item 1), part number, 955.631.232.10 on the right main headlight, press on, and close both locking bars.
10. Place a new main headlight cap (Figure 3, Item 1), part number, 955.631.231.10 on the left main headlight, press on, and close both locking bars.
11. Position both breather adapters (Figure 3, Item 3), part number, 997.631.451.01 on the connections of both main headlight caps so that the outlet is pointing downward.
12. In order to ensure that the plug connections for both main headlights are plugged in completely when installing them, spray the plug housing all the way around (Figure 4, Item 1) with lubrication oil, part number, 000.043.206.16.
13. Install both main headlights according to the Workshop Manual, Group 9, Chapter 94 15 19.
14. Ignition "On".
15. Carry out a function check of the headlights.
16. Ignition "Off".
17. Enter the workshop service action into the Warranty and Maintenance booklet
Warranty Info:
Parts Required:
Tools:
Flat screwdriver (medium)
Flat screwdriver (small)
Hot air gun
Reference:
Cayenne (9PA) Technical Manual, Group 9:
> Repairs: 94 15 19 - Removing/Installing main headlights
Disclaimer