Porsche 1D6 Manual

Technical Information Tequipment
27/07 ENU 6690 6
Trailer Hitch (I-no. 1D6)
Vehicle Type: Cayenne/Cayenne S/Cayenne Turbo/Cayenne Turbo S
Model Year: As of 2003 up to 2006
Filing: This Technical Information bulletin replaces bulletin Group 6, #6/04, dated 6-23-06
Situation: Retrofitting
Concerns: ONLY for vehicles with "trailer hitch" preparation [up to MY ’04: I-no. 1D8, the preparation comes as
standard as of MY ’04].
Information: The Cayenne can be retrofitted with a trailer hitch. Note the following special features:
• Permissible hitch tongue weight of 308 lbs (140 kg)
• Totally versatile fording depth
• Standard 7–pin socket (USA version)
• Payload following installation, restricted by higher vehicle curb weight!
• Gross vehicle weight rating and axle load must not be exceeded!
Figure 1
Parts Info: 955.044.002.74 ⇒Trailer hitch, mechanical – USA
The following parts must be ordered separately for pre-MY ’06 vehicles:
2007© Porsche Cars North America, Inc. Tequipment Aug 15, 2007
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66690 ENU 27/07 Technical Information
N 909.892.01 8x ⇒Hexagon-head bolt M14 x 1.5 x 100 (for securing trailer hitch
to body)
Parts List:
Figure 2
Some items shown in Figure 2 are not available for the North American market.
955.722.004.01 1x Trailer hitch – complete (not shown)
955.613.164.00.6N3 1x Control switch
⇒ Figure 2 -D-
955.613.166.00.01C 1x Control switch installation frame
⇒ Figure 2 -E-
955.044.000.28 1x Ball bar, removable – complete
⇒ Figure 2 -G-
955.722.030.00 1x Plug, USA/Canada variant
⇒ Figure 2 -H-
––– 1x Trailer hitch control unit
⇒ Figure 2 -I-
N 910.292.03 8 x Hexagon-head bolt, M12 x 1.5 x 100 (vehicles as of MY ’06)
⇒ Figure 2 -K-
955.647.153.00 2 x Clip for KESSY
⇒ Figure 2 -L-
N 909.975.01 1x Hose holder
⇒ Figure 2 -M-
N 102.856.01 4x Screw, M6 x 25
⇒ Figure 2 -N-
N 904.759.02 1x Sheetmetal press nut
⇒ Figure 2 -O-
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Technical Information Tequipment
27/07 ENU 6690 6
N 103.383.01 1x Screw, M5 x 12 ⇒ Figure 2 -P-
N 910.260.01 1x Internal serration screw, M10 x 20
⇒ Figure 2 -R-
––– 10 x Tie-wrap, 150 mm (not shown)
––– 1x 10 A fuse (not shown)
––– 3 x 15 A fuse (not shown)
––– 1x 25 A fuse (not shown)
––– 1x 30 A fuse (not shown)
––– 1x “No tail light” sticker – marking for USA only (not shown)
Spare Parts: 955.612.506.00 1 x Electric wire harness
955.618.040.02 1x Control unit, trailer hitch
955.044.000.28 1x Ballbar
955.722.030.00 1x Plug
955.612.520.00 1 x Wire sleeve
Materials: ––– –– Double-sided adhesive tape and/or adhesive (commercially
available)
––– –– Silicon remover (commercially available)
Tools: Torque angle torque wrench Nr.88 Disassembly tool Nr.21
Socket-wrench insert, Torx T20/25/27/30 Screwdriver, hexagon socket a/f 5
Open-ended/ring wrench, a/f 8, 10 Socket-wrench insert a/f 17, 19, 21
Screwdriver Saw or electric knife
Ratchet Steel drill bit, Ø up to 8.0 mm
Side cutters Tap, M12 x 1.5 or M14 x 1.5
Drill Round/flat file
Plastic wedge Scraper
Knife Electric torch
Notes: For further information on using and maintaining the trailer hitch, see CayenneOwner’s Manual; topics:
“Trailer hitch”; “Trailer load”; “Trailer”; etc.
ATTENTION
Saws or knives can damage adjacent
• components.
⇒Mask the cutting area.
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66690 ENU 27/07 Technical Information
⇒Be very careful when working (sawing) in this area.
Work Procedure: 1 Preparatory work.
1.1 Switch off ignition and remove ignition key.
WARNING
Working on the vehicle electrical system
• Risk of short circuit and fire.
⇒Disconnect and cover the battery.
⇒Route electric wires without tension so that no chafing occurs.
⇒Secure electric wires to existing wires/components using tie-wraps and/or wrapping tape.
1.2 Disconnect and cover the battery, then connect the power supply while the vehicle is in the
workshop
⇒ Technical Information ’270600 Battery: Battery care and maintenance/power
supply’.
1.3 Remove rear bumper
⇒ Workshop Manual ’635019 Removing and installing rear bumper -
section on "Removing"’.
1.4 Removesidetrimpanelforrearrightluggagecompartment
⇒ Workshop Manual ’700319
Removing and installing side trim panel for rear luggage compartment - section on
"Removing"’.
Figure 3
1.5 Remove warning triangle and first-aid kit in the
rear right wheel arch area
⇒ Figure 3 -B-.
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Technical Information Tequipment
27/07 ENU 6690 6
Figure 4
1.6 Remove foam insert from the inner side panel
⇒ Figure 4 -inset-.
Figure 5
1.7 ONLY for vehicles with level adjustment
control unit:
Pull up clamps on level adjustment control
unit support
⇒ Figure 5 -arrow- (if fitted) and
swivel control unit out of the bracket.
Figure 6
1.8 Loosen the two clips
⇒ Figure 6 -A,
arrows- on the support for the rear-end
control unit
⇒ Figure 6 -A1- together with
the tilt sensor control unit (
⇒ Figure 6 -A2- if
installed
⇒ Workshop Manual ’966319
Removing and installing control unit for tilt
sensor - section on "Removing"’)andlay
support aside
⇒ Figure 6 -B-.
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66690 ENU 27/07 Technical Information
Figure 7
2 Fit the trailer hitch and foam parts
⇒ Workshop
Manual ’669019 Removing and installing trailer hitch
- section on "Installing"’.
2.1 Check that the screw threads and contact
surfaces (
⇒ Figure 7 -A-) for fitting the trailer
hitch are not dirty. Clean them and re-cut the
threads using an M12 x 1.5 tap, or using an
M14 x 1.5 tap on older vehicles, if necessary.
2.2 Fit the trailer hitch and tighten hand-tight at
theleftandrightusingeightnewscrews(M12
x 1.5 x 100, or M14 x 1.5 x 100 on older
vehicles)
⇒ Figure 7 -B-.
Figure 8
2.3 Align screw guides for the trailer hitch
⇒ Figure 8 -A- symmetrically with respect to
the eight screw heads
⇒ Figure 8 .
2.4 Tighten trailer hitch fully.
Tightening torque 100 Nm (74 ftlb.) +90°
Figure 9
2.5 Fit foam part on trailer hitch
A– Foam part for mechanical trailer
hitch
B– Foampart—NotForUSA
2.5.1 ONLY for vehicles with spare wheel
carrier:
Select foam part for the relevant
model year and cut it according to
the marking
⇒ Figure 9 .
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Technical Information Tequipment
27/07 ENU 6690 6
Figure 10
2.5.2 Select foam part
⇒ Figure
10 -A- corresponding to the trailer
hitch version and adapt it to suit the
trailer hitch at the underside, close
to the mounting point for the spare
wheel carrier lock using a knife
⇒ Figure 10 -B-.
2.5.3 Remove double-sided adhesive tape
from the section you cut off and
stick it on the cut surface
⇒ Figure
10 -B, arrow-.
2.5.4 Pull strips of film off the adhesive
pads on the underside of the foam
part and stick adapted foam part to
the trailer hitch.
Use more double-sided adhesive
tape if necessary (commercially
available).
2.5.5 ONLY for vehicles with spare wheel carrier:
Screw off holder for spare wheel mount lock from the standard carrier and screw
it to the trailer hitch using the four screws
⇒ Figure 11 -arrows-. ⇒ Workshop
Manual ’446019 Removing and installing holder for spare wheel mount lock’.
Tightening torque 10.5 Nm (8.0 ftlb.) +/-1 Nm (+/-0.5 ftlb.)
Figure 11
Position electric lines for lock
in foam part and connect plug
connections
⇒ Figure 11 -A and
B- to lock.
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Figure 12
2.5.6 ONLY for vehicles with spare wheel
carrier and KESSY system:
Secure right KESSY antenna
⇒ Figure 12 -B1- to the trailer hitch
support using two clips
⇒ Figure
12 -A, arrows-.
Figure 13
2.5.7 ONLY for vehicles with KESSY
system:
Insert antennas and wire harness
into the foam part
⇒ Workshop
Manual ’966719 Removing and
installing antenna for KESSY/PAS -
section on "Installing"’.
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Technical Information Tequipment
27/07 ENU 6690 6
Figure 14
3 Route and connect electric wire harness.
3.1 Remove rubber sleeve from side panel and
guide all electric wire harness connectors
through the bore
⇒ Figure 14 -A, arrow- and
into the passenger compartment.
Insert pre-fitted rubber sleeve into the bore on
the body.
3.2 Guidethewireharnessintothevehicleasfar
as necessary to ensure a sufficient distance
from the trailer hitch (clip on underside
⇒ Figure 14 -B, arrow-) and from the
exhaust system
⇒ Figure 14 -B, X-.
Figure 15
3.3 Trailer hitch connection diagram
A– 16-pin connector (black) →trailer
hitch control unit, connector A
C– 12-pin connector (blue) →trailer
hitch control unit, connector C
D– 10-pin connector (white) →switch
(not for USA)
E– 6-pin connector (green) →4DR
connection point (trailer hitch prepa-
ration)
Figure 16
3.4 Route electric wire harness as follows:
Connector E (green) →connector strip for
existing wiring for trailer hitch
⇒ Figure 16
-E-;
Route wire harness from inner side panel
behind the CD autochanger and amplifier to
the control unit installation position and fix in
place.
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Figure 17
3.5 Install trailer hitch control unit
⇒ Workshop
Manual ’669619 Removing and installing
trailer hitch control unit - section on
"Installing"’.
3.5.1 Fit M5 sheetmetal press nut
⇒ Figure 17 -A- to the control unit
support
⇒ Figure 17 -B-.
3.5.2 Fit trailer hitch control unit
⇒ Figure
17 -C- on the control unit support
and secure with the M5 x 12 screw
⇒ Figure 17 -D-.
Tightening torque 3.5 Nm
(2.5 ftlb.) +/-0.5 Nm (+/-0.5 ftlb.)
Figure 18
3.6 Plug in connector A (black
⇒ Figure
18 -A1-)/connector B (red
⇒ Figure
18 -A2-)/connector C (blue
⇒ Figure
18 -A3-) from top to bottom on the trailer
hitch control unit.
Position foam sleeve (prevents rattles and
chafing) back over connector B
⇒ Figure
18 -B-.
Figure 19
3.7 Plug in connector E (green,
⇒ Figure 19 -A-)
on connector strip for 4DR connection point
at the top.
3.8 ONLY for vehicles with level adjustment
control unit:
Fit level adjustment control unit
⇒ Figure
19 -B-) into bracket and press clamp into
control unit support.
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Technical Information Tequipment
27/07 ENU 6690 6
Figure 19
4 Concluding work.
A– Marking for trailer hitch — USA
B–NotforUSA
C–NotforUSA
4.1 Make a cut-out for the ball hitch in the rear
apron.
4.1.1 Draw the embossed marking for
the relevant trailer hitch variant on
theinsideoftherearapronwitha
clearly visible pen
⇒ Figure 19.
4.1.2 Carefully make the cut-out
according to the marking.
4.1.3 Smooth off cut edges with a file or scraper.
4.2 Install rear apron
⇒ Workshop Manual ’635519 Removing and installing rear apron - section
on "Installing"’.
ONLY for vehicles with a mechanical trailer hitch:
Fit cover for rear apron.
4.3 Fit fuses for the trailer hitch electrical system
⇒ Workshop Manual ’9784IN Fuse carrier’.
4.3.1 Remove fuse box cover from dashboard at the right.
4.3.2 Insert the following fuses into the slots:
Worldwide: Slots 1 = terminal 30 (trailer left)/3 = terminal 30 (switched) and 5 =
terminal 30 (trailer right) →15 A each
ONLY for trailer hitch: Slot 19 = terminal 30 →25 A
4.3.3 Install fuse box cover on dashboard at the right.
4.4 Install side trim panel for rear right luggage compartment.
⇒ Workshop Manual ’700319
Removing and installing side trim panel for rear luggage compartment’
4.5 Place first-aid kit and warning triangle in the side panel area, fix them in place and fit cover of
side trim panel for the rear right luggage compartment.
4.6 Connect battery and fit battery cover.
4.7 Code trailer hitch using the PIWIS Tester 9718 .
4.7.1 Read out the fault memory for the trailer hitch control unit and erase it.
4.7.2 Code the trailer hitch control unit.
⇒ Workshop Manual ’669619 Removing and
installing trailer hitch control unit’
4.7.3 Once coding is complete, read out the fault memories of all systems. Correct any
existing faults and then erase them.
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66690 ENU 27/07 Technical Information
Working Time: 66 90 23 00 –Retrofitting mechanical trailer hitch–
Includes: Removing and installing rear apron and side trim panel for rear
luggage compartment, cutting out rear apron, coding trailer
hitch.
Labor time: 360 TU
Important Notice: Porsche Cars N.A Technical Bulletins are intended for use by professional technicians, not a "Do-it-yourselfer." They are written to inform these technicians of conditions that may
occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Special tools may be required to perform certain operations identified in these bulletins. Use of tools
and procedures other than those recommended in these bulletins may be detrimental to the safe operation of your vehicle. Properly trained technicians have the equipment, tools, safety instructions
and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your Porsche Dealer for
information on whether your vehicle may benefit from the information. Part numbers listed in these bulletins are for reference only. Always check with your authorized Porsche dealer to verify correct part
numbers. © Porsche Cars North America, Inc.
Dealership
Distribution
Routing
Service Manager
Asst. Manager
_______
_______
Shop Foreman
Warranty Admin.
_______
_______
Service Technician
Service Technician
________
________
_______
_______
_______
_______
_______
_______
Dr. Ing. h.c. F. Porsche AG is the owner of numerous trademarks, both registered and unregistered, including without limitation the Porsche Crest®, Porsche®, Boxster®, Carrera®, Cayenne®,
Cayman™, Tiptronic®, VarioCam®, PCM®, 911®, 4S®, and the model numbers and distinctive shapes of Porsche’s automobiles such as, the federally registered 911 automobile. The third party
trademarks contained herein are the properties of their respective owners. Porsche Cars North America, Inc., believes the specifications to be correct at the time of printing. However, specifications,
standard equipment and options are subject to change without notice. Printed in the USA
Aug 15, 2007
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