Body - Sport Design Package Installation
Cayenne7/04 6658
Binder - 6, Body Equipment
Date: 11-29-04
SportDesign Package Installation Instructions
Vehicle Type:
Cayenne/Cayenne S/Cayenne Turbo
Model Year:
As of 2003 (3)
Concerns:
SportDesign Package (I no. 2D1 & 2D2) installation Instructions. Not for vehicles with:
Spare wheel carrier (I No. 1G3), Off-Road Design Packages (I No. PM1, PM2, PM3, PM4, PM5, PM6, PA3, PA4) and mudguards.
Information:
The SportDesign Package, which further emphasizes the Cayenne's sporty character, has been developed, tested and approved for the following combinations:
- Complete SportDesign Package for Cayenne/Cayenne S and Cayenne Turbo consists of front spoiler, lower section of rear apron with bow, side member panels and rear spoiler.
- SportDesign Package without side member panels for vehicles with running board or rockrail consists of front spoiler, lower section of rear apron with bow and rear spoiler.
- SportDesign Package containing only a set of side members.
Other combinations are not permissible!
Parts Information:
Danger!
Risk of injury due to vehicles slipping or tipping 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 take-up points provided.
> Check the correct seating of the support plates by raising the vehicle slightly and conducting a visual inspection.
> In order to ensure that the vehicle does not lift off the support plates during assembly work, the vehicle must be secured on the lifting platform, or the shift in the center of gravity must be offset by a corresponding load in the vehicle, when units are removed or supported.
> The guidelines of the lifting platform manufacturers and accident prevention regulations must be observed.
Caution!
Risk of property damage - if the vehicle is raised incorrectly.
> Lifting or supporting the vehicle at unsuitable take-up points can lead to damage to the vehicle.
> Lift the vehicle only at the approved take-up points.
> Raising the vehicle in the sill area will lead to deformation of body parts and to leakage in the underbody area.
Caution!
Damage or warping can occur on components - as a result of improper painting and drying processes.
> Observe the specifications and instructions for the painting of plastics as contained in the Paint Manual.
> During the painting and drying process, place the parts free of tension on the painting fixtures provided for this purpose.
Caution!
Damage to components in the area to be cut - due to jig saw or knife.
> Mask the area to be cut with tape.
> Only work (saw) in this area with great care.
Caution!
Damage (risk of destruction or damage) to the accessories or to the overall vehicle - due to cleaning the vehicle in automatic car washes.
> Accessories such as spoilers might not be adequately recognized by the light barrier under certain circumstances. In cases of doubt, consult the car wash operator or only manually wash the vehicle.
Caution!
Damage (risk of destruction or damage) to the accessories or to the overall vehicle - due to misuse or improper use.
> Rapid opening of the rear lid can cause damage to the spoiler or rear wiper. Check and optimize the gap dimensions of the rear lid. Open rear lid carefully.
> Never use the spoiler to push the vehicle.
Caution!
Damage (risk of destruction or damage) to the accessories or to the overall vehicle due to the smaller overhang angle and ground clearance and reduced fording depth.
> The bottom of the spoiler can scrape on the ground when the vehicle is loaded or unloaded or driven in parking garages or on off-road terrain with very steep inclines.
> Avoid steep access and exit ramps wherever possible.
> Adapt your driving style to the local situation.
Material:
Paint, corresponding to color code of vehicle - refer to Paint Manual Rubbing Alcohol, Acetone
Tools:
Work Procedure:
1. Parts of the SportDesign Package which required painting, except for the satin aluminium surfaces, are to be painted as specified in the Paint Manual.
2. Installing front spoiler.
2.1 Remove front apron (Technical Manual, Group 9, Part ID 6315).
2.2 Remove front spoiler (original) (Part ID 6603).
2.3 Install fog lights (SportDesign Package) in new front spoiler (Part ID 9464).
2.4 Mount front spoiler (SportDesign Package) on old front apron (Part ID 6603).
2.5 Mount front apron (Part ID 6315).
Important Note:
Check body gap dimensions.
a. Mount upper section of rear spoiler.
Note:
The number of fastening screws for the upper section of the rear spoiler (SportDesign Package) will be increased on the production line from three to five. The change will be implemented shortly.
3.1 Remove old rear spoiler upper section (Part ID. 6658).
3.2 Mount new seals (parts list Item A3/A4) on the right and left of rear spoiler lower section.
3.3 Check number of fastening points on new rear spoiler upper section:
- Rear spoiler upper section with 5 fastening points (Figure 4, Item A): Mounting rib on left and right for snap nut (arrow).
- Rear spoiler upper section with 3 fastening points (Item B): does not have any mounting ribs.
3.4 Only for rear spoiler upper sections with 5 fastening points:
3.4.1 Mount snap nuts to rib (Figure 4, arrow) on right and left of rear spoiler upper section.
3.4.2 Transfer dimensions Y = 2.6 mm and Z = 4.8 mm on the left and right to rear spoiler lower section (Item B).
3.4.3 At each of these positions, bore a hole with ID = 5.0 mm (Item A).
Note:
Holes should be bored with the rear window open.
Protect the body from paint damage, e.g. with a suitable wooden support, while drilling.
3. Install the rear spoiler upper section with the old screws (KD 6658).
Note:
Use new plugs for screw holes.
3.6 Only for rear spoiler upper sections with 5 fastening points:
Tighten both sheetmetal screws ST 4.2 x 16 (see Figure 5, Item C).
3.7 If necessary, tighten left/right seals (Figure 3) once more.
3.8 Stick on protective film (will be introduced in the parts scope at a later date).
Note:
If the protective film is damaged or does not adhere properly, remove the protective film and order a new set, refer to the Porsche Electrical Parts Catalog (PET) for the part number.
3.8.1 Remove protective film (if present) from the rear lid. If necessary, remove seal or paint marks by polishing.
3.8.2 Clean grease, wax, and dust off the bonding surface of the rear lid.
3.8.3 With the rear window closed, mark the position of the seal (A) with adhesive strips (B). Distance between seal and adhesive tape (see Figure 6, inset). X = 1 mm
Note:
For clarification, Figure 6 shows the adhesive strips and the adhered protective film.
3.8.4 Stick on protective film such that it is free of blisters.
Note:
Do not touch the bonding surface of the protective film.
3.8.5 Remove adhesive strips.
3.8.6 Close the rear window and check position of protective film with respect to the seal.
4. Installing lower section of rear spoiler.
4.1 Remove rear apron and lower section of rear apron (Part ID 6355).
4.2 Mount lower section of rear apron (SportDesign Package) onto rear apron (Part ID 6355).
4.3 Clip the snap nuts onto appropriate parts of the covers and the lower section of the rear apron.
4.4 Secure covers (parts list Item K/L) on lower section of the rear apron with screw (A) and clamping washers (parts list Item I).
4.5 Mount bow (parts list Item F) to rear apron.
4.5.1 Only vehicles with trailer coupling:
Cut out bow with jig saw or knife.
Note:
Mask the sawing area with tape. There are several cut-out versions marked on the inside of the bow.
Item: Cutout for trailer coupling:
A Trailer coupling, USA
B Trailer coupling, electrical
C Trailer coupling, manual
4.5.2 Attach bow to rear apron.
Note:
Ensure that the holding straps are seated correctly.
4.5.3 Secure bow to lower section of rear apron with screws (B).
4.6 Mount rear apron (Part ID 6355).
5. Install right side member panel.
5.i Preparatory work.
5.1.1 Remove centre trim (Part ID 5193).
5.1.2 Remove fender cover (Part ID 6618).
5.1.3 Unscrew screw from wheel housing liner (A) and screw from wing (B).
5.1.4 Remove wheel spoiler for rear wheel (A).
Note:
Carefully lever the wheel housing cover in order to unscrew the screws.
5.2 Mount holder (parts list Item V).
Note:
To securing the holder, use the screws from the wheel spoiler of the rear wheel.
Tightening torque: 1.5 Nm (1.0 ftlb.)
5.3 Remove water drainage plug (A) from underbody.
5.4 Insert clips (parts list Item W) into the bores for the water drainage plugs.
Note:
Align the centering mark towards the center of the vehicle.
5.5 Insert retaining strip (parts list Item S) into the holder and secure with screws (parts list Item Z) and screw (parts list Item M).
Tightening torque:
Screws Item Z = 6 Nm (4.5 ftlb.) Screw Item M = 2.5 Nm (2.0 ftlb.)
5.6 Clean grease, wax and dust off the bonding surface of the side member. Afterwards do not touch the bonding surface.
5.7 Position side member panel (parts list Item P) and screw in screws (A and B).
Note:
Do not fully tighten screws.
5.8 Align side member panel.
Note:
During alignment, pull the protective film (A) from the adhesive tape on the side member panel (starting in the middle of the panel). Ensure that the gap between the sill and side member panel is uniform along its entire length.
5.8.1 Rear flap for side member panel:
Distance between lower edge of sill and upper edge of side member panel: X = 5 mm.
5.8.2 Side member panel center:
Distance between lower edge of sill (A) and upper edge of side member panel (B): X = 5 mm.
5.8.3 Side member panel fender cover:
Distance between upper edge of side member panel and lower edge of wing: X 13 mm.
5.9 Press side member panel into place with rubber roller. Contact pressure: mm. 50 - 80 N
5.10 Position side member panel on retaining strip and secure using expanding rivets (parts list Item X).
5.11 Tighten screws for securing the side member panel in rear wheel arch.
Tightening torque: 1.5 Nm (1.0 ftlb.)
5.12 lighten screw for front wheel housing liner and screw for wing.
Tightening torque:
Screw for wing 8 Nm (6.0 ftlb.)
Screw for wheel housing liner 1.5 +/- 0.5 Nm (1.0 +/- 0.5 ftlb.)
5.13 Mount fender cover (Part ID 6312).
Note:
If necessary, replace grommet for fender cover (parts list Item Al) and clips (parts list Item N).
5.14 Mount center trim (Part ID 5193).
5.15 The left side member panel is mounted in the same way.
6. Only vehicles with trailer coupling: Mount cover for the trailer coupling.
7. Set the function test for the lights and fog lights.
Working Time:
References:
Paint Manual, 4/6/8-cylinder: Chapter "Painting plastics"
Cayenne Technical Manual (9PA), Group 5/6
> Repairs
51 93 19 - Removing and installing middle cover
63 15 19 - Removing and installing front apron
63 15 37 - Disassembling and assembling front apron
63 55 19 - Removing and installing rear apron
63 55 37 - Disassembling and assembling rear apron
66 03 19 - Removing and installing front spoiler
66 58 19 - Removing and installing rear spoiler
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