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Home >> Porsche >> 2008 >> Cayenne Turbo (9PA) V8-4.8L Turbo >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Technical Service Bulletins >> Engine Controls - 'Turbo Power Kit' Installation >> Work Procedure >> Part 1

Part 1

Work Procedure:

1. Preparatory work

1.1 Drive the vehicle onto a lifting platform and position it --> Workshop Manual '4X00IN01 Lifting the vehicle'.

1.2 Connect charger to battery --> Workshop Manual '2706 Battery'.

1.3 Remove the engine compartment cover, above the lambda sensor connectors --> Workshop Manual '700219 Removing and installing front trim (engine compartment) - section on "Removing".





1.4 Disconnect plug connections for the lambda sensors (two on each side; left side - see --> Figure 4) and release lines --> Workshop Manual '267619 Removing and installing primary catalytic converter on V8 4.8-litre DFI engines - section on "Removing"'.

1.5 Remove front wheels --> Workshop Manual '44051900 Removing and installing wheel - section on "Removing"'.

1.6 Remove engine guard --> Workshop Manual '108019 Removing and installing engine guard (underbody panel) on DFI engines - section on "Removing"'.

2. Convert exhaust system and rear cardan shaft

2.1 Exhaust system

2.1.1 Remove exhaust system --> Workshop Manual '260119 Removing and installing exhaust system on DFI engines - section on "Removing"'.





2.1.2 Disconnect plug connections (--> Figure 5 -arrows-) to the transfer gear, support transfer gear with the transmission jack and loosen cross member from transfer gear to body --> Workshop Manual '396519 Removing and installing transfer gear - section on "Removing"'.

2.1.3 Remove universal joint screw on the steering shaft and slide universal joint up --> Workshop Manual '48901900 Removing and installing steering gear - section on "Removing"'.

2.1.4 Remove the primary catalytic converter --> Workshop Manual '267619 Removing and installing primary catalytic converter on V8 4.8-litre DFI engines - section on "Removing"'.

2.1.5 Remove lambda sensors upstream of the primary catalytic converter (one on each side) --> Workshop Manual '246919 Removing and installing lambda sensor upstream of catalytic converter on DFI engines - section on "Removing"' and downstream of the primary catalytic converter (on each side) --> Workshop Manual '247319 Removing and installing lambda sensor downstream of catalytic converter on DFI engine - section on "Removing"'.

2.1.6 Install lambda sensor (4 ea.) on the new primary catalytic converter --> Workshop Manual '246919 Removing and installing lambda sensor upstream of catalytic converter on DFI engines - section on "Installing"' and --> Workshop Manual '247319 Removing and installing lambda sensor downstream of catalytic converter on DFI engines - section on "Installing"'.

Tightening torque 45 Nm (33 ftlb.) ± 5 Nm (± 3.5 ftlb.)

2.1.7 Install primary catalytic converter with new seals (2 seals for each catalytic converter) and new hexagon nuts (8 nuts for each catalytic converter) --> Workshop Manual '267619 Removing and installing primary catalytic converter on V8 4.8-litre DFI engines - section on "Installing"'.

2.1.8 Slide universal joint down and secure to steering shaft with a new screw (M10 x 35) --> Workshop Manual '48901900 Removing and installing steering gear - section on "Installing"'.

Tightening torque 35 Nm (26 ftlb.) +90 degrees

2.1.9 Secure transfer gear cross member to the body using four new hexagon-head bolts (M10 x 80).

Tightening torque 50 Nm (37 ftlb.) +90 degrees

2.2 Rear cardan shaft

2.2.1 Remove rear cardan shaft --> Workshop Manual '393519 Removing and installing rear cardan shaft - section on "Removing"'.





2.2.2 Fit center bearing holder for new cardan shaft at the body and align it with the pins (--> Figure 6 -arrows-). Loosely pre-fit holder using six new hexagon-head bolts (M10 x 30, --> Figure 6 -1-) --> Workshop Manual '393519 Removing and installing rear cardan shaft - section on "Installing"'.

2.2.3 Secure rear cardan shaft to the rear axle differential flange using six new cheese head bolts (M10 x 45) and three plates --> Workshop Manual '393519 Removing and installing rear cardan shaft - section on "Installing"'.

Tightening torque 30 Nm (22 ftlb.) +90 degrees





2.2.4 Secure rear cardan shaft to the transfer gear flange using three new hexagon-head bolt (M12 x 1.5 x 65, --> Figure 7 -1-), three A13 washers (--> Figure 7 -2-) and three M12 hexagon nuts (--> Figure 7 -3-) --> Workshop Manual '393519 Removing and installing rear cardan shaft - section on "Installing"'.

Tightening torque 60 Nm (44 ftlb.)

2.2.5 Tighten the six hexagon-head bolts (M10 x 30, --> Figure 6 -1-) on the center bearing holder --> Workshop Manual '393519 Removing and installing rear cardan shaft - section on "Installing"'.

Tightening torque 60 Nm (44 ftlb.)

2.2.6 Centre the cardan-shaft center bearing using the centering tool 9680 and tighten the two hexagon-head bolts (M8 x 16, --> Figure 6 -2-) --> Workshop Manual '393519 Removing and installing rear cardan shaft - section on "Installing"'.

Tightening torque 20 Nm (15 ftlb.)

2.2.7 Install exhaust system --> Workshop Manual '260119 Removing and installing exhaust system on DFI engines - section on "Installing"'.

3. Add letter to engine number.





The engine number is located on the left side close to the oil pan/short engine flange in direction of travel --> Figure 8.

NOTE:
If there is no space for the letter "S" at the end of the engine number, it can even be stamped under the first number after the engine type "M48/51".

3.1 Add the letter "S" to the standard engine number "M48/51..." on the engine housing (--> Figure 8 -inset, arrow-).

3.2 Install engine guard --> Workshop Manual '108019 Removing and installing engine guard (underbody panel) on DFI engines - section on "Installing"'.

4. ONLY for vehicles manufactured up to May 2008 (CW 22):
Convert the tie rods





4.1 Remove tie rod at the left and right --> Figure 9 --> Workshop Manual '48791900 Removing and installing tie rod - section on "Removing"'

4.2 Remove the joint boot on both tie rods and install on the new tie rods with a new O-ring (50.0 x 2.0) and a new clip (one on each side).
4.3 Install new tie rods --> Workshop Manual '48791900 Removing and installing tie rod - section on "Installing"'.

Tie rod to pivot bearing: Tightening torque 90 Nm (67 ftlb.)

Lock nut on tie-rod ball: Tightening torque 90 Nm (67 ftlb.)

Axial tie rod to steering rack: Tightening torque 100 Nm (74 ftlb.) +10 degrees

5. ONLY for vehicles manufactured up to May 2008 (CW 22):
Convert the brake system





5.1 Remove brake caliper and brake disc at the front

5.1.1 Remove front wheel housing liner --> Workshop Manual '505619 Removing and installing front wheel housing liner - section on "Removing"'.

5.1.2 Cover wheel carrier and lower steering knuckle with a cloth. Disconnect brake hose at the top (--> Figure 10 -arrow-) and close off line at the vehicle side with a stopper if necessary.





5.1.3 Disconnect electric plug connection for brake pad wear indicator (--> Figure 11 -1-) and disengage lines form the bracket (--> Figure 11 -2-).

5.1.4 Remove front brake caliper --> Workshop Manual '47391900 Removing and installing front brake caliper - section on "Removing"' (--> Figure 11).

5.1.5 Remove front brake disc --> Workshop Manual '46501950 Removing and installing front brake disc - section on "Removing"'.

5.2 Clean the flat and centering surfaces of the brake disc at the wheel carrier and then apply a thin layer of Optimoly TA.





5.3 Remove cover plate (brake anchoring plate) and install new brake anchoring plate on the wheel carrier using three new hexagon-head bolts (M8 x 12) on each side (--> Figure 12 -1-).

Tightening torque 20 Nm (15 ftlb.)
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