Body - Running Board Installation
Cayenne9/03 6626
Binder - 6, Body Equipment
Replace pages 1 & 2 of bulletin Group
6, # 9/03 dated 8-22-03 with this page.
Date: 9-19-03
Vehicle Type:
Cayenne S / Cayenne Turbo
Model Year:
As of '03 (3)
Concern:
Running Board Installation Instructions, not for vehicles with rockrail.
Filing:
Replace page 1 and 2 of Cayenne bulletin Group 6, # 9/03, dated 8-22-03 with this updated page.
Information:
The running board with integrated guard protects the side member when going off-road driving and provides easier entry and helps when loading the roof transport system. It is made of high-quality aluminium and has a striking appearance.
Parts Information:
Warnings:
Note:
To correctly position the holder, a template must be prepared (see Template). After making a copy, the side lengths of the template must be checked. Take a ruler and verify that the template is the correct scale. There is the possibility that during printing and/or the copier process + or - scaling occurred. Template reference points are 150 mm X 60 mm. If your printed or copied template measurements when compared against a ruler do not match, make printer/copier output adjustments accordingly.
Danger!
Risk of injury due to vehicles slipping or tilting off lifting platform! - caused by improper alignment of the lifting platform arms or their support plates, as well as by raising, supporting or removing units on raised vehicles.
> Align the vehicle evenly between the lifting platform columns.
> Lift the vehicle only at the lifting points provided.
> Check the correct seating of the support plates by raising the vehicle slightly and conducting a visual inspection.
> In order to assure that the vehicle is not lifted off the support plates during assembly work, the vehicle must be secured on the lifting platform when removing or supporting units or the shift in the center of gravity must be compensated with corresponding loads in the vehicle.
> In addition, the guidelines of the lifting platform manufacturer and local accident prevention regulations must be observed.
Caution!
Danger of material damage - due to raising the vehicle incorrectly.
> Lifting or supporting the vehicle at unsuitable lifting points can lead to damage to the vehicle.
> Lift the vehicle only at the approved lift points, see owner's manual.
> Raising the vehicle in the sill area will lead to the deformation of body parts and to leakage in the underbody area.
Materials:
1 x M8 screw x 50
1 x M10 nut
2 x M8 washer
2 m Electrical wire 1.0 sq.
Tools:
Torx screwdriver T25, T30
Filler / Scissors
Ratchet
Rivet gun for blind rivet nut M8 made of steel
Socket wrench insert a/f 10, 13
Torque wrench
Nutdriver hexagon socket a/f 5
Open-end/ring wrench, a/f 10
Approved platform lift
Work Procedure:
1. Preparatory work.
1.1 Clean sill area of vehicle - refer to Cayenne Owner's Manual.
1.2 Print out template (see Template) and check dimensions. Glue the template onto cardboard and cut out.
1.3 Position the vehicle on the platform lift and lift using the lifting points (Figure 003, arrows) - see Technical Manual.
1.4 Remove side member trim and rear spray protection - see Technical Manual.
2. Remove both front holders of the side member trim.
2.1 Unscrew screw (A) and remove holders for the side member trim (B).
Note:
The holders for the side member trim will no longer be needed.
2.2 Only vehicles with Porsche Active Suspension Management (PASM). Standard equipment on Turbo, optional on Cayenne S.
2.2.1 Unscrew screws (A) and remove compressor bracket (B).
Note:
To avoid damage, attach the compressor on existing components.
2.2.2 Unscrew screws (C) and remove holder for the compressor bracket (D).
2.2.3 Remove threaded bushing from the holder of the compressor bracket.
Note:
The threaded bushing will no longer be needed.
2.2.4 Unscrew screw (A) and remove accumulator (B). Note: To avoid damage, attach accumulator on existing components.
2.2.5 Unscrew screw (C) and remove holders for the side member trim.
3. Schematic diagram of the arrangement of blind rivet nuts in the underbody (Figure 007).
Note:
The contact surfaces of the blind rivet nuts and running board holders must be checked. Remove dirt and undersealing if necessary.
3.1 Insert the bund rivet nuts M8 using the rivet gun.
3.2 Alternative tool for installing the M8 blind rivet nuts. Note: Only use if a suitable rivet gun is not available!
Important:
The friction surfaces between the washers and the screw threads must be coated with grease.
3.2.1 Functional structure: Turn M8 screw x 50 (A) with M10 nut (B) and two M8 washers (C) in the blind rivet nut (D).
3.2.2 Function: Insert blind rivet nut in the hexagon holes in the vehicle frame or rail and tighten the screw.
Tightening torque: 28 Nm (21 ftlb.).
Unscrew screw and remove nut and washers. Check that the blind rivet nut is seated properly.
4. Positioning the holder with fitting template.
4.1 Function: Position the fitting template with the contact points (A) on the side member.
4.2 Position the holder on the contact surface (B).
4.3 Tighten the hexagon-head flat screws.
Tightening torque: 26 Nm (19 ftlb.)
5. Install both front holders for the running board.
5.1 Position both front holders and screw in the hexagon-head flat screws.
5.2 Align holder with template (see Step 4) and tighten the hexagon-head flat screws.
Tightening torque: 26 Nm (19 ftlb.)
5.3 Only vehicles with Porsche Active Suspension Management (PASM). Standard equipment on Turbo, optional on Cayenne S.
5.3.1 Position the right front holder (A) with the holder of the compressor bracket (C) and screw in the hexagon-head flat screws (B).
5.3.2 Align holder with template (see Step 4) and tighten the hexagon-head flat screws.
Tightening torque: 26 Nm (19 ftlb.)
5.3.3 Position the compressor bracket and tighten with screws.
Tightening torque: 23 Nm (17 ftlb.)
5.3.4 Install left front holder.
5.3.5 Unscrew the bolts (A) for the accumulator.
5.3.6 Position left front holder and screw in the hexagon-head flat screws and bolts for the accumulator.
5.3.7 Align holder with template (see Step 4) and tighten the hexagon-head flat screws.
Tightening torque: 26 Nm (19 ftlb.)
5.3.8 Position the accumulator and tighten with screws.
Tightening torque: 23 Nm (17 ftlb.)
6. Position center holder and screw in the hexagon-head flat screws (A).
6.1 Align holder with template (see Step 4) and tighten the hexagon-head flat screws.
Tightening torque: 26 Nm (19 ftlb.)
7. Position rear holder and screw in the hexagon-head flat screws (A).
7.1 Align holder with template (see Step 4) and tighten the hexagon-head flat screws.
Tightening torque: 26 Nm (19 ftlb.)
8. Attaching running board.
Note:
Raise or lower the vehicle to working height with the platform lift.
8.1 To ensure the correct seat of the sealing lip for the vehicle side member, place an electrical wire (2 m long / 1.0 sq.) behind the sealing lip on the running board.
8.2 Position running board and tighten using the hexagon-head flat screws (A).
Tightening torque: 26 Nm (19 ftlb.)
8.3 Pull out the electrical wire carefully from the running board and check the correct seat of the sealing lip.
8.4 Position the rear wheel housing liner and tighten with screws (A) to the running board.
8.5 Position the front wheel housing liner and tighten with screws.
Working Time:
Literature:
Cayenne Technical Manual (9PA), Group 4/5
> Repair
4 - Lifting the vehicle
43 15 19 - Removing and installing compressor for the level control system
50 56 19 - Removing and installing wheel housing liners, front
51 93 19 - Removing middle cover
53 69 19 - Removing and installing wheel housing liners, rear
Cayenne Owner's Manual
> Chapter vehicle "Care" and "Washing"
Before printing template see "Note" under Warnings.
Disclaimer