Electrical - Multiple Malfunctions
Cayenne8/04 9436
Binder - 9, Electrical System
Date: 10-9-04
Electrical Malfunctions Due To Sticking Brake Light Switch
Vehicle Type:
Cayenne/Cayenne S/Cayenne Turbo
Model Year:
'03 (3) and '04 (4)
Concerns:
Distance between brake light switch and lower dashboard cover is too small.
- Lower dashboard cover to contact the brake light switch,
- Brake light switch sticks or is mechanically damaged.
Information:
If the distance between the lower dashboard cover in the driver's footwell and the brake light switch is too small, parts of the lower dashboard cover could press on the plug shoe of the brake light switch. This can lead to the brake light switch sticking or becoming mechanically damaged.
Additionally, a malfunctioning brake light switch could be linked with the following possible fault types:
- the brake lights are continuously lit
- the cruise control does not function at times
- the PSM fails
- the vehicle cannot be started
In order to increase the distance between the lower dashboard cover and the brake light switch, thereby preventing a malfunction of the brake light switch, a foam rubber strip is to be installed on the brake light switch retainer as of the stated introduction dates.
On vehicle produced before the stated introduction dates, the foam rubber strip is to be installed on the brake light switch retainer whenever there is a customer complaint.
Introduction:
May 10, 2004, as of the following VINs.
9P 14L 4128 Cayenne/USA
9P 14L A7 6579 Cayenne S/USA
9P 64L A9 4587 Cayenne Turbo/USA
Parts Information:
Tools:
Torx wrench T15
Work Procedure:
- Checking the operation of the brake light switch.
- Installing foam rubber strips to the brake light switch retainer.
1. Remove the cover under the dashboard in the driver's footwell; see POSES, Workshop Manual, Cayenne, Group 7, 70 22 19 - Removing and installing cover under dashboard.
2. Checking the operation of the brake light switch.
2.1 Switch on ignition.
2.2 Press brake pedal and check if the brake lights light up.
2.3 Take foot off of the brake pedal and check if the brake lights go out. Switch off ignition after the function test is completed.
- Brake light switch is intact, continue with Step 4.
- Brake light switch is faulty, continue with Step 3.
Caution!
Insufficiently secured brake light switch after disassembly and reassembly.
> Only Installed brake light switch once.
> Replace disassembled brake light switch with a new brake light switch.
3. Replacing brake light switch (Figure 1, arrow), see POSES, Workshop Manual, Cayenne, Group 9, 94 36 19 - Removing and installing brake light switch.
4. Install foam rubber strips to the brake light switch retainer.
4.1 Pull protective film off the bonding area of foam rubber strips.
4.2 Stick the foam rubber strips left justified on the surface of the brake light switch retainer (Figure 2, arrow).
5. Install cover under the dashboard.
Working Time:
References:
POSES, Workshop Manual, Cayenne:
> Group 7: 70 22 19 - Removing and installing cover under instrument panel
> Group 9: 94 36 19 - Removing and installing brake light switch
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