Campaign - W531 VARTA(R) Battery Replacement
Cayenne15/04 W531
Date: 4-8-05
Binder - 2, Fuel, Exhaust & Engine Elc.
W531 - Replacing VARTA Batteries
(Workshop Service Action)
Vehicle Type:
Cayenne / Cayenne S
Model Year:
M.Y. 2004 (4) to M.Y. 2005 (5)
Concern:
Replacing VARTA Batteries.
Equipment:
Battery 70 AH (I No. J0L), battery 95AH (I No. J1U)
Information:
This is to inform you of a voluntary Workshop Service Action on a certain range of 2004 to 2005 model year Cayenne (V6) and Cayenne S vehicles. Due to a manufacturing fault, batteries installed in the vehicles do not meet the required level of quality.
After a complete discharge of the battery it is not assured that the battery can be recharged back to full capacity while driving or with a battery charger. This can lead to the possibility that the vehicle can not be started due to a low/dead battery.
Action Required:
1. Fill new battery with electrolyte and charge (I No. J1U only).
2. Read date of production on the installed VARTA battery and depending on the result, replace the VARTA battery.
3. Replace battery according to following list:
Affected vehicles:
A total of 756 U.S. and 12 Canadian vehicles fall within the scope of this Workshop Service Action.
Very Important!
Use the VIN range below as a general guideline. The VIN can be checked in the Porsche e-DCS/WWS for confirmation of an open recall campaign. Refer to Attachment "A" to determine if a particular vehicle is eligible for this recall campaign (or service action). Attachment "A" for W531 VINs is an electronic attachment only, and will be accessible via e-DCS Document repository.
This attachment will not be available in a printed form and therefore cannot be sent to your dealership location. Also, the VIN can be checked via the VRU (Voice Response System) for any open listing.
The affected Vehicle Identification Numbers are contained in the VIN Ranges shown.
Work Procedure:
See Attachment "B"
Time Allowance:
Parts Information:
Tool:
Administrative Procedure:
See Attachment "C"
Attachment "A" VIN List
For complete VIN List, please consult e-DCS Document Repository/Service Actions.
Or, use the VIN range from page one as a general guideline. The VIN can be checked in the Porsche e-DCS/WWS for confirmation of an open recall campaign. Attachment "A" for W531 VINs is an electronic attachment only, and will be accessible via e-DCS Document repository. This attachment will not be available in a printed form and therefore cannot be sent to your dealership location. Also, the VIN can be checked via the VRU (Voice Response System) for any open listing.
Attachment "B"
Work Procedure:
Read date of production on the installed VARTA battery and depending on the result, replace the battery.
1. Introductory work.
1.1 Fill new Moll battery (95 AH), part No. 955.611.095.30 with electrolyte and charge.
Note!
Observe the warning notes and safety regulations according to > Workshop Manual "2706 Battery" "General information on the vehicle battery".
1.1.1 Fill battery with diluted sulphuric acid (electrolyte) up to the "Max." marking.
1.1.2 When filling the battery, shake slightly so that air bubbles will escape and that the acid will make complete contact with the battery plates.
1.1.3 After waiting approx. 20 minutes, check the acid level again and if necessary fill up to "Max." marking.
1.1.4 Connect the battery to a suitable battery charger and charge. Electronic chargers which can charge according to "IU characteristic" should preferably be used for charging (automatic charging process, overcharging is not possible).
When charging with other chargers, the charging current must not be higher than 1/10 of the nominal capacity of the battery to be charged (e.g. 9.5 A for a 95 AH battery). The charging time or voltage must be monitored.
Important!
Do not use a "Quick" charging unit.
1.1.5 Disconnect battery from charger.
1.1.6 Write the battery charging date on a piece of paper and attach this to the battery if the new battery will not be installed in the vehicle immediately.
2. Read the date of production of the installed VARTA battery.
Note!
In order to read the date of production of the installed battery, the front two fastening screws must be unscrewed from the seat frame of the left front seat. The fastening screws (part No. N. 910.192.01) are coated and must be replaced after they are unscrewed in accordance with
> Workshop Manual "720119 Removing and installing front seat - chapter "Removing and installing".
2.1 Fold back left front seat according to > Workshop Manual "720119 Removing and installing front seat - chapter on "Removing", take off cover of battery and check the date of production on the negative terminal of battery (see Figure 1).
Item A Calendar week Item B Year of production
2.2 Date of production as of CW 44/04 - continue to Step 4, it is not necessary to replace the battery.
Date of production before CW 44/04 - continue to Step 3 and replace the installed battery.
3. Replace VARTA battery.
Note!
Observe the information concerning removing and installing battery according to > Workshop Manual 2706 "General information on the vehicle battery".
3.1 Remove VARTA battery according to > Workshop Manual "270619 Removing and installing battery chapter on "Removing"."
3.2 Read battery capacity on the removed battery (see Figure 2-A-) and install new battery according to the following list:
3.3 Check new battery according to > Workshop Manual 2706 "General information on the vehicle battery" and recharge battery if necessary.
Note!
Batteries not installed immediately in the vehicle are to be checked according to > Technical Information "Group 2 # 3/02 - Battery care and maintenance prior to vehicle delivery" and recharged if necessary.
3.4 Install new battery according to > Workshop Manual 270619 Removing and installing battery - chapter on "Installing".
Note!
If a battery must be replaced, the values indicated on the battery maintenance sheet must be measured according to > Technical Information "Group 2 # 3/02 - Battery care and maintenance prior to vehicle delivery" and documented. The completed battery maintenance sheet must be filed.
4. Concluding work.
Attention!
Material damage and torque loss at the seat screw connection. The fastening screws for the seats are coated and must be replaced after being unscrewed.
> Before screwing in the new fastening screws, clean the thread holes with a M10 x 1.5 tap.
4.1 Fold left front seat forward according to > Workshop Manual 270619 Removing and installing battery-chapter on "Installing" and tighten the new fastening screws, part No. N 910.192.01 to tightening torque of 45 Nm (33 ftlb.).
4.1.1 Carry out work instructions after disconnecting the battery according to > Workshop Manual 901000 Work instructions after disconnecting the battery.
5. Enter the Workshop Service Action into the Warranty and Maintenance booklet.
Attachment "C"
Administrative Procedure, Workshop Service Action W531 Warranty claims should be submitted via e-DCS
Note:
Always check for open recall status under the appropriate e-DCS menu options.
Affected VINs:
See Attachment "A"
Damage Code:
W531 066 000 1 (for Scope 1)
W531 066 000 2 (for Scope 2)
Labor Operation:
Will be automatically inserted along with the necessary parts when the damage code is entered.
Repair Code:
1 (for scope 1)
2 (for scope 2)
Time Units:
Parts Required:
Will be automatically inserted along with the necessary parts when the damage code is entered
Reference:
See Workshop Manual
2706 19 Removing and installing battery-chapter on "Removing and installing"
2706 Battery
720119 Removing and installing front seat
9010 00 Work instructions after disconnecting battery
90 Battery trickle charging
Technical Information Bulletin
Group 2 # 2/02 - Charging battery during workshop visit
Group 2 # 3/02 - Battery care and maintenance prior to vehicle delivery
Disclaimer