Work Procedure
1. Preparatory Work1.1 Connect charger to battery (See Workshop Manual, Group 2: 2706 IN).
1.2 Remove wheel hub caps and loosen drive shaft lock nuts in the front and rear.
1.3 Remove front and rear wheels (See Workshop Manual, Group 4: 44 05 19).
1.4 Remove exhaust system (See Workshop Manual, Group 2: 26 01 19).
1.5 Only vehicle with rear-differential lock:
Remove rear-differential lock servo motor (See Workshop Manual, Group 3: 39 77 19).
1.6 Unscrew fastening screws from cardan shaft (See Workshop Manual, Group 3: 39 35 19) and drive shafts to rear wheel drive assembly (See Workshop Manual, Group 4: 42 21 19) and tie up cardan shaft and drive shafts.
1.7 Unscrew fastening screws from stabilizer on rear axle housing (See Workshop Manual, Group 4: 42 90 19).
1.8 Remove rear final drive (See, Workshop Manual, Group 3: 39 01 19).
1.9 Press rear drive shafts with universal drive shaft/wheel hub extractor 87-1 out of wheel hubs (See Workshop Manual, Group 4: 42 21 19).
2. Convert rear axle (RA).
2.1 Remove brake caliper (See Workshop Manual, Group 4: 47 41 19) and brake disc (Workshop Manual, Group 4: 46 53 19).
2.2 Disengage the cable of the foot operated parking brake and remove the brake shoes.
2.3 Remove speed sensor (See Workshop Manual, Group 4: 45 11 19).
2.4 Remove wheel bearing (See Workshop Manual, Group 4: 42 58 19).
2.5 Unscrew fastening screws from brake cover panel and take off brake cover panel.
2.6 Install brake cover panel (955.352.802.50) with screws (N 014 739 10 and N 909 768 01) onto wheel carrier.
2.7 Install wheel bearing (See Workshop Manual, Group 4: 42 58 19).
2.8 Install speed sensor (See, Workshop Manual, Group 4: 45 11 19).
Tightening torque: 6 Nm (4.5 ftlb.)
2.9 Engage the brake shoes and cable of the foot operated parking brake.
2.10 Install new brake disc (955.352.401.50) (See Workshop Manual, Group 4: 46 53 19). Tightening torque: 15 Nm (11 ftlb.)
Note:
Use new screw (N 910 282 01).
2.11 Only vehicles with 200 Hz self-leveling sensors.
2.11.1 Remove self-leveling sensor (See Workshop Manual, Group 4: 43 19 19).
2.11.2 Install new self-leveling sensor (955.331.077.20). See Workshop Manual "431919 Removing and installing rear level sensor - section on Installing".
Tightening torque: 4.5 Nm (3 ftlb.)
2.12 Install new brake caliper (955.352.422.61) (See Workshop Manual, Group 4: 47 41 19). Note: Use new screw (N 105 556 01).
2.13 Install brake pads (955.351.939.50) (See Workshop Manual, Group 4: 46 36 20). Tightening torque: Brake pad retaining pin, 30 Nm (22 ftlb.)
2.14 Adjust foot-operated parking brake (See Workshop Manual, Group 4: 46 83 16). Note: Screw in screw plug (N 910 380 01) in brake disc.
3. Concluding work on rear axle (RA).
3.1 Insert drive shafts in wheel bearing housing (wheel carrier), if necessary pull in with assembly fixture T10206 and tie up with tie-wraps.
Note:
Lightly grease axle nuts only on mounting-face ring as well as teeth of the drive shaft with Optimal TA aluminium paste.
3.2 Install final drive (See Workshop Manual, Group 3: 39 01 19).
Tightening torque: 90 Nm (67 ftlb.) + 90°
Note:
Use new nuts (N 104 029 01) and screws (N 102 112 01).
3.3 Install cardan shaft and drive shafts with new fastening screws to rear wheel drive assembly (See Workshop Manual, Group 3: 39 35 19/Group 4: 42 21 19).
3.4 Attach stabilizer to rear axle housing (See Workshop Manual, Group 4: 42 90 19).
Tightening torque: 50 Nm (37 ftlb.)
Note:
Use new screws (N 908 476 01).
3.5 Only vehicle with rear differential lock:
Install servo motor for rear differential lock with new sealing ring (955.332.649.00) (See Workshop Manual, Group 3: 39 77 19).
Tightening torque: 10 Nm (7.5 ftlb.)
3.6 Check oil level for rear final drive and top up if necessary (See Workshop Manual, Group 3: 39 90 35).
4. Install exhaust system (POSES, Workshop Manual, Group 2: 26 01 19).
5. Preparatory work for converting front axle (FA).
5.1 Remove front engine compartment trim panel (See Workshop Manual, Group 7: 70 02 19), front wiper arms (See Workshop Manual, Group 9: 92 25 19) and cover for cowl panel (See Workshop Manual, Group 6: 66 44 19).
5.2 Remove complete engine guard (See Workshop Manual, Group 1:10 80 19 Removing and installing engine guard - section on "Removing".
5.3 Bleed pressure accumulator and front spring strut. To do this, connect PIWIS Tester, select the menu item "Bleed level adjustment in level adjustment system".
5.4 Remove brake caliper (See Workshop Manual, Group 4: 47 39 19) and brake disc (See Workshop Manual, Group 4: 46 50 19).
5.5 Unscrew fastening screws from brake cover panel and remove brake cover panel.
5.6 Remove wheel bearing housing (wheel carrier) (See Workshop Manual, Group 4: 40 50 19).
5.6.1 Pull off connector from self-leveling sensor, lateral acceleration sensor, rpm sensor and compact connector.
5.6.2 Push out tie rod on wheel bearing housing (wheel carrier) with press-out tool T10187.
5.6.3 Remove brake line with brake hose from wheel carrier. To do this, unscrew fastening screws from brake hose holder at the top and brake line holder.
5.6.4 Move drive shaft with universal drive shafts/wheel-hub extractor No. 87-1 approx. 20-25 mm into wheel hub.
5.6.5 Unscrew fastening screw for spring strut on lower trailing arm.
5.6.6 Push out lower ball joint on wheel bearing housing with press-out tool T10187.
5.6.7 Secure wheel bearing housing from falling, press out upper ball joint on wheel bearing housing with pressout tool T10187 and take out wheel bearing housing.
5.7 Remove fastening screw/nut for suspension/stabilizer on the stabilizer.
5.8 Screw off air connection on spring strut.
5.9 Unscrew eccentric screws and fastening nuts from lower trailing arm and remove trailing arm (See Workshop Manual, Group 4: 40 17 19).
6. Convert Steering.
6.1 Remove tie rod from steering rack (See Workshop Manual, Group 4: 48 79 19).
6.2 ONLY for vehicles with Servotronic steering gear (I No. 1N3) prior to production and delivery date 2-28-2005 or with a VIN lower than 9P65LA91996 - Cayenne Turbo/USA
6.2.1 Remove previous steering gear and install new steering gear (955.347.011.11) See Workshop Manual "489019 Removing and installing steering gear".
6.2.2 Remove previous Servotronic control unit and install new control unit (955.618.047.01) See Workshop Manual "486919 Removing and installing Servotronic control unit".
Note:
Use a new sealing ring and lug hose clamp on the steering gear!
6.3 Mount tie rod (955.347.031.50) to steering rack (See Workshop Manual, Group 4:4879 19). Tightening torque: 100 Nm (74 ftlb.)
7. Convert front axle (FA), spring strut area, hydraulic mount, anti-roll bars and wheel carriers.
7.1 Unscrew fastening screws for spring strut in engine compartment and remove spring strut See Workshop Manual "433019 Removing and installing front spring strut (air spring) - section on "Removing"'.
7.2 Convert spring strut.
7.2.1 Fill spring strut with air (See Workshop Manual, Group 4: 43 01).
7.2.2 Remove upper trailing arm, Figure 3, item A. To do this, remove fastening nuts, Figure 3, item B and locking screws, Figure 3, item C.
7.2.3 Fit trailing arm with level sensor, Figure 3, item D to new spring strut using new screws (N 102 902 04) and nuts (N 102 861 02). Only vehicles with 200 Hz self-leveling sensors. Install new self-leveling sensor (955.341.075.20) with upper trailing arm.
7.2.4 Remove fastening screw and lock nut from suspension/stabilizer (Figure 3, Item F) and install with new screw (N 105 760 01) and nut (N 104 029 01) on new spring strut.
Note:
Tighten lock nut when stabilizer has been mounted on suspension/stabilizer.
7.2.5 Unscrew nut from lateral acceleration sensor (Figure 3, Item E) and fasten lateral acceleration sensor with screw (N 904 407 02) and lock nut (N 023 00 28) to new spring strut.
7.3 Install spring strut.
7.3.1 Replace hydraulic mount by rubber mounting (955.341.242.50) for trailing arm (See Workshop Manual, Group 4: 40 20 55).
7.3.2 Insert spring strut, position with auxiliary pin, and screw down fastening screws (N 910 400 01) in engine compartment.
Tightening torque: 50 Nm (37 ftlb.) + 90°
Note:
It is necessary to enlist the help of a second person.
7.3.3 Install trailing arm with new eccentric screw (955.331.217.00) and lock nut (N 102 686 02).
Note:
Eccentric screw and lock nut are only tightened to the prescribed tightening torque during suspension alignment!
7.3.4 Mount spring strut on trailing arm with screw (N 105 326 01) and lock nut (N 103 353 02).
Note:
Tighten lock nut in vehicle position (See Workshop Manual, Group 4: 43 30 19, Installing front spring strut, Instructions).
7.4 Mount stabilizer on suspension/stabilizer with screw (N 105 668 01) and lock nut (N 104 029 01).
Note:
Tighten lock nut in vehicle position.
7.5 Tighten lock nut from suspension/stabilizer (Figure 3, Item F). Tightening torque: 110 Nm (81 ftlb.)
7.6 Install front wheel carrier (See Workshop Manual, Group 4: 40 50 19).
7.6.1 Insert wheel carrier in lower ball joint and position drive shaft.
7.6.2 Install wheel carrier to upper ball joint with nut at top with (N 909 413 01) and bottom with (N 909 771 01)
7.7 Mount brake line (A) (955.355.581.50) to brake hose (B).
Note:
Tighten brake line to brake hose only after mounting the brake line to brake caliper.
7.8 Secure brake hose and brake line to wheel carrier using screws, Figure 4, Inset. Tightening torque for cable holder screw, Figure 4, item C: 9 Nm (6.5 ftlb.)
Tightening torque for brake hose holder screw, Figure 4, item D: 30 Nm (22 ftlb.)
7.9 Mount tie rod ball joint to wheel carrier with nut (N 909 771 01).
Tightening torque: 90 Nm (67 ftlb.)
7.10 Pull in drive shaft with assembly fixture T10206 and install new lock nut (955.341.640.00).
7.11 Lift wheel carrier into normal vehicle position (See Workshop Manual: Group 4: 42 90 19, Installing stabilizer, Instructions) and tighten spring strut to trailing arm and nut from stabilizer
7.12 Connect connector from self-leveling sensor, lateral acceleration sensor, rpm sensor and compact connector.
7.13 Connect air connection on spring strut. Tightening torque: 3 Nm (2 ftlb.)
8. Convert front axle brake area and brake ventialtion.
8. Clip in air-guide element Figure 5, Item I, (955.351.117.00/118.00) to spring strut and fasten with screws (N 105 475 01) and nuts (N 102 058 02).
8.2 Install brake cover panel (955.351.801.51) with fastening screws (N 010 237 12) to wheel carrier.
Tightening torque: 20 Nm (15 ftlb.)
8.3 Install brakes.
8.3.1 Install front brake disc (955.351.401.60) (See Workshop Manual, Group 4: 46 50 19).
Tightening torque: 14 Nm (10.5 ftlb.)
Note:
Use new screw (N 910 282 01).
8.3.2 Install front brake caliper (955.351.421.61/422.61) (See Workshop Manual, Group 4: 47 39 19).
Tightening torque: 270 Nm (200 ftlb.)
Note:
Use new screws (N 906 854 02).
8.3.3 Install brake line to brake caliper and tighten brake line to brake hose (Figure 3, Item A and B).
8.3.4 Install front brake pads (See Workshop Manual, Group 4: 46 36 20). Tightening torque:
Brake pad retaining pin, 30 Nm (22 ftlb.)
8.3.5 Fasten warning contact with cable holder (944.612.627.00) to brake line.
8.4 Bleed brake system (See Workshop Manual, Group 4: 47 01 07).
9. Concluding work on front and rear axles.
9.1 Tighten front and rear drive shaft with lock nut. Tightening torque: 500 Nm (370 ftlb.)
9.2 Install cover for cowl panel (See Workshop Manual, Group 6: 66 44 19).
9.3 Install front wiper arms (See Workshop Manual, Group 9: 92 25 19).
10. Converting engine.
10.1 Remove left charge air cooler (See Workshop Manual, Group 2: 21 43 21).
10.2 Unclip throttle body cover (See Workshop Manual, Group 1: 10 83 19).
10.3 Remove air box for throttle housing (Y-shaped pipe) (See Workshop Manual, Group 2: 24 35 19).
10.4 Remove pressure pipe together with pressure hose. Only the right-hand side is described here.
10.4.1 Loosen clamp, Figure 6, item A and pull bypass hose off pressure pipe and pressure hose, Figure 6, item B.
10.4.2 Lever out wire clip, Figure 6, item C using a screwdnver and remove pressure pipe and pressure hose, Figure 6, item B. Put wire clip back into installation position immediately.
10.5 Loosen hose clamp, Figure 7. item A and remove left pressure hose, item B.
10.6 Install pressure pipe with left pressure hose.
10.6. Slide left pressure hose (955.110.837.00) onto left pressure pipe (955.110.368.00) and join hose clamp (N 024 505 6). Observe assembly position (Figure 8, inset A)!
10.6.2 Fasten pressure pipe with left pressure hose with hose clamp to turbocharger. Marks (inset B) must align.
10.7 Install pressure pipe with right pressure hose.
10.7.1 Slide right pressure hose (955.110.838.00) onto right pressure pipe (955.110.367.00) and join with hose clamp (N 024 505 6). Observe assembly position (Figure 9, inset)!
10.7.2 Insert pressure pipe with right pressure hose (A) in turbocharger. Wire clip must engage audibly.
10.7.3 Fasten bypass hose (B) with clamp to pressure pipe with right pressure hose.
10.8. Install left charge air cooler (See Workshop Manual, Group 2: 21 43 21).
10.8.1 Slide ventilation guide (955.575.339.40) onto left charge air cooler (955.110.803.41), engagement will be felt.
10.8.2 Move left charge air cooler with ventilation guide into installation position.
10.8.3 Position sealing ring, Figure 11, item A, (N 106 203 01) between left charge air cooler (B) and pressure pipe with pressure hose (C).
10.8.4 Secure left charge air cooler and pressure pipe with clamp (955.110.807.00). Marks (cut-out D) must be opposite each other.
10.8.5 Fasten upper left pressure pipe with screws (N 103 231 01) to left charge air cooler.
Tightening torque: 10 Nm (7.5 ftlb.)
10.8.6 Screw down charge air cooler.
Tightening torque: 8 Nm (6 ftlb.)
10.8.7 Insert air guide (955.575.331.40) in front of charge air cooler sideways.
10.9 Install right charge air cooler similar to the left vehicle side.
10.10. Concluding work on engine.
10.10.1 Clip retaining clip, Figure 12, Item Afor airbag sensor line.
10.10.2 Install air box for throttle housing (Y-shaped pipe) (See Workshop Manual, Group 2: 24 35 19).
10.10.3 Clip in throttle body cover (See Workshop Manual, Group 1:10 83 19).
10.10.4 Stamp the letter S under the slash of the standard engine number in the crankcase.
10.10.5 Install complete engine guard (See Workshop Manual, Group 1:10 80 19).
10.10.6 Install front apron (See Workshop Manual, Group 6: 63 15 19).
10.10.7 Install front trim panel (engine compartment) (See Workshop Manual, Group 7: 70 02 19).
11. Mount wheels (See Workshop Manual, Group 4: 44 05 19).
Tightening torcue: 160 Nm (118 ftlb.).
12. Program contrDl units and perform suspension alignment.
12.1 General information on the DME control unit
12.1.1 With the introduction of the V8 Turbo KIT, the following new diagnostis software number (DSN) and data records are available:
12.1.2 DME Turbo KIT data records can only be programmed with the PIWIS Tester using V6.0 or higher.
12.1.3 Prerequisites for successful programming:
- Turbo data record for standard vehicle - without I No. E81- must be programmed on the DME control unit;
- DME control unit must be adapted (taught) to suit the vehicle (including immobilizer code!);
- Immobilizer code and increased performance enabling code must be enabled in IPAS.
12.2 Program DME control unit.
12.2.1 Connect PIWIS Tester and switch on ignition.
12.2.2 Select vehicle type and DME control module. Proceed with [>>].
12.2.3 Select Program control unit. Proceed with [>>].
12.2.4 Enter vehicle type, model year, transmission, and emission standard. Proceed with [>>].
12.2.5 Enter immobilizer code. Proceed with [>>] and confirm with [F7].
12.2.6 Enter enabling code. Proceed with [>>].
12.2.7 Program by pressing [F8].
12.2.8 When programming has ended, start vehicle and then switch off ignition.
12.3 Remove level adjustment control unit and install new control unit (955.618.301.41) (See Workshop Manual, Group 4: 43 16 19).
Note:
The control unit will be calibrated as is necessary when a suspension alignment is performed.
12.4 General information on the level adjustment control unit. The following new DSN has been newly added:
DSN
1001 New DSN for Turbo KIT scopes
12.4.1 A Turbo KIT level adjustment control unit can only be coded/taught with the PIWIS Tester with V6.0 and higher.
The following function is complete:
Coding:
- the level adjustment control unit should be replaced and recoded for Turbo KIT
- the level adjustment control unit can only be coded if the Turbo KIT DME data records have been successfully programmed.
- codurig is valid for Turbo KIT: Cayenne V8 RoW Turbo KIT
The TLIrbo KIT level adjustment control unit cannot be taught/coded on a vehicle without Turbo KIT
12.5 Code level adjustment control unit.
12.5.1 Select vehicle type and level adjustment control unit.
12.5.2 Select coding and code country selection.
12.5.3 Read out fault code and erase it if necessary.
12.6 Disconnect PIWIS Tester, switch off ignition and disconnect ballery charger.
12.7 Perform complete suspension alignment (See Workshop Manual, Group 4: 44 IN).
Note:
The differences from adjustment values for the Cayenne without Increased performance are listed in the table.
13. Check main and fog light settings and adjust if necessary. (See Workshop Manual, Group 9: 94 15 19 and 94 16 19.)