47 tw tightening torques for brake hydraulics

WARNING: Porsche Stability Management does not work without values for the2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, Booster2003-2008 BRAKESBrakes - Hydraulics, Regulator, Booster47 TW TIGHTENING TORQUES FOR BRAKE HYDRAULICS - AS OF MY 2003(ALL MODELS EXCEPT CAYENNE S TIO TITAN)TIGHTENING TORQUESLocation Explanation Type BasicvalueBrake pressure line to brakemaster cylinder, brake hose,Tightening 10.5Thread M10/M12distributor, brake caliper andtorque ftlb.hydraulic unitMount for hydraulic unit support Thread M6 x 10Mount for intermediate piece Thread M6 x 14Brake caliper to wheel carrierfront axleBrake caliper to wheel carrier rearaxle47 01 07 BLEEDING THE BRAKE SYSTEM - AS OF MY 2003 (ALL MODELSEXCEPT CAYENNE S TIO TITAN)BLEEDING THE BRAKE SYSTEMThread M16 x 1.5 x 48 x 33(Replace screws and locknuts after each removal.)Thread M14 x 1.5 x 40(Replace screws and locknuts after each removal.)Connecting line to brake caliper Thread M10 x 1Bleeder screw on brake caliper Thread M10 x 1Brake pressure line to brakecaliperThread M10 x 1Cap screws for brake lines Thread M10 x 1Brake boosterBrake booster to brake mastercylinderThread M8M8 threadTighteningtorqueTighteningtorqueTighteningtorqueTighteningtorqueTighteningtorqueTighteningtorqueTighteningtorqueTighteningtorqueTighteningtorqueTighteningtorque7.5ftlb.7.5ftlb.200ftlb.133ftlb.9.5ftlb.10.5ftlb.10.5ftlb.10.5ftlb.19ftlb.19ftlb.Tolerance1+/-0.5ftlb.+/-0.5ftlb.+/-1.5ftlb.+/-0.5ftlb.+/-0.5ftlb.+/-2 ftlb.+/-3 ftlb.Tolerance2

2. Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure isapprox. 2.0 bar.2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, Boostercurrent brake pressure.• Danger of personal injury and material damage when the hydraulicunit is not calibrated.--> After assembling the hydraulic unit, a static test and a swap test must be carried out with the Porsche SystemTester.--> After assembly of the brake master cylinder or the hydraulic unit, the pressure sensor must be calibratedwith the Porsche System Tester.NOTE:• Observe brake fluid quality. Use only new DOT 4 brake fluid.1. Open reservoir.• The brake fluid change interval is two years, using Super DOT 4 brakefluid.• This brake fluid is available under the following part numbers: Containerquantity: 1 liter = 000.043.203.66. 30 liters = 000.043.203.67.Fig. 1: Bleeding device connected to brake fluid reservoirCourtesy of PORSCHE OF NORTH AMERICA, INC.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterNOTE:• Always bleed both bleeder valves on the brake caliper.• Bleed the outer bleeder valve first.3. Continue the bleeding procedure at the brake calipers. Do so in the following sequence: rear right/rearleft/front right/front left.4. Use a transparent hose and a collecting bottle to check the escaping brake fluid is clean and free of airbubbles and to determine the amount of brake fluid used.5. Open each bleeder valve until clear, bubble-free brake fluid emerges.6. Tighten the bleeder valves to the specified tightening torque and remove the bleeder hoses.Fig. 2: Brake fluid reservoirCourtesy of PORSCHE OF NORTH AMERICA, INC.7. Remove bleeding device from brake fluid reservoir and screw cap on. The brake fluid level in the brake fluidreservoir must be between the MIN and MAX markings once the vehicle has been filled and bled. Adjust thebrake fluid level if necessary.8. Generate vacuum in brake booster by starting engine. Check brake-pedal travel and pedal feel.Checking after bleeding

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterNOTE:• If the pedal travel is too long or the pedal feels too soft when applied, carryout the following procedure.• Two workers are required for this.• Also carry out this procedure if the brake hydraulic system was largelyempty.Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure isapprox. 2.0 bar.1. Open bleeder valve at rear on right-hand side, then push the brake pedal all the way down about 5 times andtap the brake caliper gently several times with a rubber hammer during the bleeding process.2. Hold for 2 - 3 seconds after each depression, then release pedal slowly. After applying pedal for the fifthtime, hold pedal down and close bleeder valve.3. Repeat this procedure in the sequence rear left/front right/front left.4. Tighten the bleeder valves to the specified tightening torque and remove the bleeder hoses.5. Remove bleeding device from brake fluid reservoir; correct brake fluid level is necessary.6. Generate vacuum in brake booster by starting engine. Check brake-pedal travel and pedal feel.47 08 55 CHANGING THE BRAKE FLUID - AS OF MY 2003 (ALL MODELSEXCEPT CAYENNE S TIO TITAN)CHECKING BRAKE FLUID LEVEL

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 3: Location of brake booster, master cylinder and fluid reservoirCourtesy of PORSCHE OF NORTH AMERICA, INC.Visually inspect brake fluid level. The brake fluid level must be between the MAX and MIN markings. Thebrake fluid reservoir is located under the left plenum panel cover -arrow- . See Fig. 3.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 4: Brake fluid reservoirCourtesy of PORSCHE OF NORTH AMERICA, INC.NOTE:• The brake fluid level must not exceed the MAX mark.CHANGING THE BRAKE FLUID• Observe brake fluid quality. Use only new DOT 4 brake fluid.• This brake fluid is available under the following part numbers: Quantitysupplied: 1 liter = 000.043.203.66; 30 liters = 000.043.203.67.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 5: Brake fluid reservoir, cap and level sensorCourtesy of PORSCHE OF NORTH AMERICA, INC.NOTE:• Observe brake fluid quality. Use only new DOT 4 brake fluid.• The brake fluid change interval is two years using Super DOT 4 brake fluid.• This brake fluid is available under the following part numbers: Quantitysupplied: 1 liter = 000.043.203.66; 30 liters = 000.043.203.67.• Drain brake fluid from every brake caliper at both bleeder valves.• Bleed the outer bleeder valve first.1. Open threaded cover of brake fluid reservoir -arrow- . See Fig. 5.2. Connect a bleeding device to the brake fluid reservoir.3. Switch on the bleeding device. Bleeding pressure is approx. 2.0 bar.4. Continue changing the brake fluid at the brake calipers. Do so in the following sequence: rear right/rearleft/front right/front left.5. Open every bleeder valve until clear, bubble-free brake fluid emerges and until the corresponding changequantity per brake caliper is reached (approx. 250 cm 3 ).6. Use a transparent hose and a collecting bottle to check the escaping brake fluid accurately for cleanliness,

3. Remove cowl panel. Refer to 66 44 19 Removing and installing cowl panel cover - as of MY 2003 (AllModels) .2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, Boosterfreedom from air bubbles and to determine the brake fluid used.7. Tighten the bleeder valves to the specified tightening torque --> 47 TW Tightening torques for brakehydraulics - as of MY 2003 (All Models Except Cayenne S TIO Titan) and remove the bleeder hoses.Fig. 6: Brake fluid reservoirCourtesy of PORSCHE OF NORTH AMERICA, INC.8. Switch off bleeding device and remove the adapter on the brake fluid reservoir. The brake fluid level in thebrake fluid reservoir must be between the MIN and MAX markings once the vehicle has been filled and bled.Adjust the brake fluid level if necessary.47 15 19 REMOVING AND INSTALLING BRAKE MASTER CYLINDER (HBZ) -AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN)PRELIMINARY WORK1. Remove both wiper arms. Refer to 92 25 19 Removing and installing wiper arm - as of MY 2003 (AllModels) .2. Remove cover in engine compartment. Refer to 70 02 19 Removing and installing front cover (enginecompartment) - as of MY 2003 (All Models) .

Fig. 8: Location of brake booster, master cylinder and fluid reservoirCourtesy of PORSCHE OF NORTH AMERICA, INC.2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterREMOVING THE BRAKE MASTER CYLINDERInstallation Location:Fig. 7: brake master cylinderCourtesy of PORSCHE OF NORTH AMERICA, INC.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterNOTE:• Before disconnecting the connector from the brake master cylinder(pressure sensor) first wipe off any moisture with a lint-free cloth.• Brake lines are to be sealed with suitable plugs.• In order to catch escaping brake fluid, place a cloth under the brakebooster.NOTE:• In the case of assembly work on the hydraulic connections, the electricalplug connections on the brake master cylinder must always be connected.This prevents the plug connections on the brake master cylinder and theinside of the plugs being splashed with brake fluid or water.• Clean any plug connections that have become dirty or damp duringremoval or fitting with a lint-free cloth.• Brake fluid on electrical contacts (even thinned brake fluid) leads tocorrosion and may cause faults in the system.• Remove any escaping brake fluid immediately; if necessary, rinse withwater and dry.The brake master cylinder is located on the left in the engine compartment, under the cowl panel cover -arrowonthe brake booster. See Fig. 8.Fig. 9: Identifying connectorsCourtesy of PORSCHE OF NORTH AMERICA, INC.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, Booster1. Push both connectors -arrows- on the plenum panel (oxygen sensor cable) from the bracket. See Fig. 9.2. Open the cable clip on the plenum panel and loosen the cable.3. Remove left plenum panel partition.Fig. 10: Brake fluid reservoir, cap and level sensorCourtesy of PORSCHE OF NORTH AMERICA, INC.4. Disconnect the connector on the cover of the brake fluid reservoir and remove the cover -arrow- . See Fig.10.5. Remove the brake fluid from the brake fluid reservoir by suction. To do this, use a double-acting hand pump.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 11: Brake fluid reservoir lugsCourtesy of PORSCHE OF NORTH AMERICA, INC.6. Bend both lugs on the brake fluid reservoir carefully outward and pull off the container upwards. See Fig. 11.7. Loosen the brake lines from the brake master cylinder.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 12: Left front wheel brake line clipCourtesy of PORSCHE OF NORTH AMERICA, INC.8. Unclip the brake line on the brake master cylinder to the left front wheel and remove the fastening clip -arrow- . See Fig. 12.9. Remove the brake master cylinder from the brake booster.10. Remove the connector of the pressure sensor at the underside of the brake master cylinder.INSTALLING THE BRAKE MASTER CYLINDERWARNING: Porsche Stability Management does not work without values for thecurrent brake pressure.• Danger of personal injury and material damage when the hydraulicunit is not calibrated.--> After assembly of the brake master cylinder or hydraulic unit, the pressure sensor must be calibrated withthe Porsche System Tester.--> To do this, calibrate the pressure sensor in the menu >> PSM >> Calibration >> Pressure sensor > PSM >> Actual values >> Security code

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterNOTE:• Cleanliness is essential when installing the brake master cylinder so thatdirt does not enter the system. This can cause faults in the system.• Replace worn sealing rings.• Pay attention to tightening torques --> 47 TW Tightening torques for brakehydraulics - as of MY 2003 (All Models Except Cayenne S TIO Titan) .Install in reverse order.1. Connect the connector of the pressure sensor to the underside of the brake master cylinder.2. Fit the brake master cylinder loosely on the brake booster. Ensure sealing ring is seated properly between thebrake master cylinder and the brake booster. Insert pushrod in the correct position in the brake master cylinder.3. Loosely fit brake lines of brake master cylinder.4. Fit the brake master cylinder on the brake booster and fit the brake lines. Fit the brake line of the left frontwheel with the clip to the brake master cylinder.Fig. 13: Brake fluid reservoir lugsCourtesy of PORSCHE OF NORTH AMERICA, INC.5. Attach the brake fluid reservoir (observe sealing rings) and check for correct seating of the lugs.6. First insert the seal of the plenum panel and then slide the plenum panel in from above. Fit the fastening

47 39 19 REMOVING AND INSTALLING FRONT BRAKE CALLIPER - AS OFMY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN)2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, Booster7. Lay the cable and fit into clip on plenum panel.8. Push the two large connectors into the bracket on the plenum panel.9. Connect the connector to the cover of the brake fluid reservoir.SUBSEQUENT WORK1. Fit the right and the rear covers. Refer to 70 02 19 Removing and installing front cover (enginecompartment) - as of MY 2003 (All Models) . and the cowl panel. Refer to 66 44 19 Removing andinstalling cowl panel cover - as of MY 2003 (All Models) .2. Install both wiper arms. Refer to 92 25 19 Removing and installing wiper arm - as of MY 2003 (AllModels) .Fig. 14: Brake fluid reservoirCourtesy of PORSCHE OF NORTH AMERICA, INC.3. Bleed the vehicle --> 470107 Bleeding the brake system - chapter on "bleeding". After the bleedingoperation, do not top up the brake fluid level above -MAX- . See Fig. 14.4. Calibrate the pressure sensor with the Porsche System Tester.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterTOOLSDesignation Type Number Explanationpiston resetting fixture commercially NR.144(replaces P83)available toolPRELIMINARY WORK1. Raise vehicle --> 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TURBO S,CAYENNE S TIO TITAN) or 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TIP,CAYENNE MAN, CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO) .2. Remove wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .REMOVING FRONT BRAKE CALLIPERInstallation Location:Fig. 15: Front brake calliperCourtesy of PORSCHE OF NORTH AMERICA, INC.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 16: Pushing brake pad away from rotorCourtesy of PORSCHE OF NORTH AMERICA, INC.NOTE:• To gain better access for removal of the brake caliper, it helps to turn thesteering fully either to the right or the left.1. Push brake pad back slightly and evenly with piston resetting fixture (replaces P83) NR.144, seeWorkshop Equipment Manual, Chapter 2.4 -direction arrow- . See Fig. 16.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 17: Identifying brake line at brake caliperCourtesy of PORSCHE OF NORTH AMERICA, INC.2. Release and unclip the plug from the wear indicator -arrow- . Loosen the brake line on the brake caliper -arrow- and collect brake fluid in a suitable container. Close off the line with suitable plugs. See Fig. 17.NOTE:• Never use an impact bolter to loosen and tighten the brake calliper on thewheel carrier.3. Remove brake calliper from wheel carrier -arrows- . See Fig. 17.INSTALLING FRONT BRAKE CALLIPERNOTE:• Replace screws and lock nuts.The brake caliper is installed in reverse order.1. Fit the brake caliper.2. Fit the brake line to the brake caliper.• Never use an impact bolter to loosen and tighten the brake calliper on thewheel carrier.• Observe correct tightening torques --> 40 TW Tightening torques for frontaxle - chapter on "Technical values".

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, Booster3. Clip in the wear indicator connector.SUBSEQUENT WORK1. Bleed the brake system --> 470107 Bleeding the brake system - chapter on "bleeding".2. Mount the wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .47 41 19 REMOVING AND INSTALLING REAR BRAKE CALLIPER - AS OFMY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN)TOOLSDesignation Type Number Explanationpiston resetting fixture commercially NR.144(replaces P83)available toolsocket-wrench insert,multiple tooth with pinguidecommerciallyavailable toolNR.33PRELIMINARY WORK1. Raise vehicle --> 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TURBO S,CAYENNE S TIO TITAN) or 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TIP,CAYENNE MAN, CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO) .2. Remove wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .REMOVING REAR BRAKE CALLIPERInstallation Location:

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 18: Brake caliperCourtesy of PORSCHE OF NORTH AMERICA, INC.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 19: Pushing brake pads away from rotorCourtesy of PORSCHE OF NORTH AMERICA, INC.1. Push brake pad back slightly and evenly with piston resetting fixture (replaces P83) NR.144, seeWorkshop Equipment Manual, Chapter 2.4 -direction arrow- . See Fig. 19.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 20: Wear indicator connector and mounting bracketCourtesy of PORSCHE OF NORTH AMERICA, INC.2. Release and unclip the connector from the wear indicator -arrow- . See Fig. 20.3. Remove cable holder for the brake line and wear indicator -arrow- . See Fig. 20.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 21: Identifying Brake line fitting and brake calliper fastenersCourtesy of PORSCHE OF NORTH AMERICA, INC.NOTE:• Never use an impact bolter to loosen and tighten the brake calliper on thewheel carrier.4. Loosen the brake line on the brake calliper -arrow- and collect brake fluid in a suitable container. Close offthe line with a suitable plug. Remove the brake calliper from the wheel carrier using a socket-wrench insert,multiple tooth with pin guide NR.33 -arrows- . See Fig. 21.INSTALLING REAR BRAKE CALLIPERNOTE:• Replace screws and lock nuts.The brake caliper is installed in reverse order.1. Fit the brake caliper.2. Fit the brake line and cable holder.• Never use an impact bolter to loosen and tighten the brake calliper on thewheel carrier.• Pay attention to tightening torques --> 42 TW Tightening torques for rearaxle - chapter on "Technical values".

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, Booster3. Clip in the wear indicator connector.SUBSEQUENT WORK1. Bleed the brake system --> 470107 Bleeding the brake system - chapter on "bleeding".2. Mount the wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .47 70 19 REMOVING AND INSTALLING BRAKE BOOSTER - AS OF MY 2003(ALL MODELS EXCEPT CAYENNE S TIO TITAN)TOOLSDesignation Type Number Explanationunlocking tool VW-tool T10189PRELIMINARY WORK1. Switch off the ignition.2. Remove both wiper arms. Refer to 92 25 19 Removing and installing wiper arm - as of MY 2003 (AllModels) .3. Remove cover in engine compartment. Refer to 70 02 19 Removing and installing front cover (enginecompartment) - as of MY 2003 (All Models) .4. Remove cowl panel. Refer to 66 44 19 Removing and installing cowl panel cover - as of MY 2003 (AllModels) .REMOVING BRAKE BOOSTERInstallation Location:

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 22: Brake boosterCourtesy of PORSCHE OF NORTH AMERICA, INC.Fig. 23: Location of brake booster, master cylinder and fluid reservoirCourtesy of PORSCHE OF NORTH AMERICA, INC.NOTE:• During assembly work on hydraulic connections, the electrical plugconnections on the hydraulic unit must always be connected. This

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, Boosterprevents the plug connections on the hydraulic unit and the inside of theconnectors being splashed with brake fluid or water.• Damp connectors must be wiped dry before disconnection.• Brake fluid on electrical contacts (even thinned brake fluid) leads tocorrosion and may cause faults in the system.The brake master cylinder is located on the left in the engine compartment, under the cowl panel cover -arrow-, together with the brake booster. See Fig. 23.Fig. 24: Identifying connectorsCourtesy of PORSCHE OF NORTH AMERICA, INC.NOTE:• Brake lines are to be sealed with suitable plugs.• To catch escaping brake fluid, place a cloth under the brake booster.1. Push both connectors -arrows- on the plenum panel (oxygen sensor cable) from the bracket. See Fig. 24.2. Open the cable clip on the plenum panel and loosen the cable.3. Remove left plenum panel partition.4. Partly remove the brake master cylinder (brake fluid reservoir) --> 471519 Removing and installing brakemaster cylinder - chapter on "removing".

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, Booster5. Disconnect the vacuum line on the brake booster.Fig. 25: Brake booster distance sensor connectorCourtesy of PORSCHE OF NORTH AMERICA, INC.6. Disconnect the connector from distance sensor of the brake booster -arrow- . See Fig. 25.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 26: Unclip the cable over the brake boosterCourtesy of PORSCHE OF NORTH AMERICA, INC.7. Unclip the cable over the brake booster from the holders -arrows- and pull upwards. See Fig. 26.8. Unclip the brake line to left front wheel out of the bracket underneath the relay carrier.9. Remove the brake master cylinder --> 471519 Removing and installing brake master cylinder - chapteron "removing".

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 27: Location of M6 screws on lower closing panelCourtesy of PORSCHE OF NORTH AMERICA, INC.10. Loosen two M6 screws on the lower closing panel -arrows- (upper screw head covered) (shown here whenfitting the brake booster, relay carrier removed). See Fig. 27.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 28: Relay carrierCourtesy of PORSCHE OF NORTH AMERICA, INC.NOTE:• If the rubber bushes stick to the holders in the plenum panel whenremoving the relay carrier, these must be fitted in the openings providedbefore being inserted again.11. Release the relay carrier in the plenum panel and hinge it to one side. To do this, unclip the six plugs in therear section of the relay carrier ( -arrow- and right marking). See Fig. 28.12. Remove the cover under the dashboard on the driver's side in the passenger compartment. Refer to 70 02 19Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 29: Stop light switch connector and holderCourtesy of PORSCHE OF NORTH AMERICA, INC.13. Pull off connector of stop light switch -arrow- and remove the complete holder. Refer to 94 36 19Removing and installing brake light switch - as of MY 2003 (All Models) . See Fig. 29.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 30: Brake booster pushrod (brake pedal side)Courtesy of PORSCHE OF NORTH AMERICA, INC.NOTE:• When loosening the pushrod of the brake booster with the unlocking toolT10189 from the pushrod of the pedal, the tool must first be inserted andthen the brake pedal pulled out into the passenger compartment.14. Release brake pedal from pushrod -arrow- of brake booster with unlocking tool. Refer to 46 05 19Removing and installing brake pedal - as of MY 2003 (All Models Except Cayenne S TIO Titan) . See Fig.30.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 31: Unlocking tool T10189Courtesy of PORSCHE OF NORTH AMERICA, INC.15. To do this, insert the unlocking tool T10189 from below into the bush on the brake pedal -arrow- . SeeFig. 31.16. Remove the four M8 lock nuts on the brake booster in the passenger compartment.17. Remove front left wheel housing liner.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 32: Front left wheel housing brake lineCourtesy of PORSCHE OF NORTH AMERICA, INC.18. Disconnect the brake line in the wheel housing on the intermediate piece -arrow- and seal with suitableplugs. See Fig. 32.19. Remove both clips for the air-conditioning lines in the plenum panel.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 33: Brake booster and bootCourtesy of PORSCHE OF NORTH AMERICA, INC.20. Pull the brake lines to the brake master cylinder and left front wheel carefully forward and press the airconditioninglines down. Make sure that the boot on the brake booster -arrow- does not get stuck in the duct tothe passenger compartment. See Fig. 33.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 34: Removing brake boosterCourtesy of PORSCHE OF NORTH AMERICA, INC.21. Carefully pull out the brake booster -direction arrow- to the front. See Fig. 34.INSTALLING BRAKE BOOSTERWARNING: Porsche Stability Management does not work without values for thecurrent brake pressure.• Danger of personal injury and material damage when the hydraulicunit is not calibrated.--> After assembly of the brake master cylinder or hydraulic unit, the pressure sensor must be calibrated withthe Porsche System Tester.--> To do this, calibrate the pressure sensor in the menu >> PSM >> Calibration >> Pressure sensor > PSM >> Actual values >> Security code

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, Booster• Calibrate the vehicle with the Porsche System Tester.• Bleed the vehicle according to the plan to ensure full operation of thebrake system.• When inserting the brake booster, make sure the brake pushrod and bootare guided correctly.• Pay attention to tightening torques --> 47 TW Tightening torques for brakehydraulics - as of MY 2003 (All Models Except Cayenne S TIO Titan) .1. Carefully pull the brake lines of the brake master cylinder and left front wheel forward and press the airconditioninglines downward.Fig. 35: Insert brake boosterCourtesy of PORSCHE OF NORTH AMERICA, INC.2. Carefully insert the brake booster -direction arrow- . See Fig. 35.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 36: Brake booster pushrodCourtesy of PORSCHE OF NORTH AMERICA, INC.3. Guide the pushrod of the brake booster through the opening in the passenger compartment. Ensure the boot isseated correctly. See Fig. 36.4. Fit the brake booster with four M8 fastening nuts.5. Press the brake pedal forward until the ball socket engages in the mounting point.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 37: Stop light switch connector and holderCourtesy of PORSCHE OF NORTH AMERICA, INC.6. Fit the holder for the stop light switch and connect the connector -arrow- . Refer to 94 36 19 Removing andinstalling brake light switch - as of MY 2003 (All Models) . See Fig. 37.7. Fit the cover on the driver's side. Refer to 70 02 19 Removing and installing front cover (enginecompartment) - as of MY 2003 (All Models) .8. Fit the clamps of the air-conditioning lines.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 38: Relay carrierCourtesy of PORSCHE OF NORTH AMERICA, INC.NOTE:• If the rubber bushes stick to the holders in the plenum panel whenremoving the relay carrier, these must be fitted in the openings providedbefore being inserted again.9. Install relay carrier in the plenum panel. To do this, fit the six connectors in the rear section of the relaycarrier ( -arrow- and right marking). See Fig. 38.

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 39: Location of M6 screws on lower closing panelCourtesy of PORSCHE OF NORTH AMERICA, INC.10. Join the closing panel using the two M6 screws -arrows- (shown here when fitting the brake booster - relaycarrier removed). See Fig. 39.

2. Install both wiper arms. Refer to 92 25 19 Removing and installing wiper arm - as of MY 2003 (AllModels) .2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, BoosterFig. 40: Front left wheel housing brake lineCourtesy of PORSCHE OF NORTH AMERICA, INC.11. Join the brake line in the front left wheel housing (remove sealing plugs).12. Install front left wheel housing liner.13. Clip the brake line to left front wheel in the bracket underneath the relay carrier in the plenum panel.14. Connect the plug on the distance sensor of the brake booster.15. Connect vacuum pipe to the brake booster.16. Fit brake master cylinder --> 471519 Removing and installing brake master cylinder - chapter on"installing".17. Fit left plenum panel partition.SUBSEQUENT WORK1. Fit the right and the rear covers. Refer to 70 02 19 Removing and installing front cover (enginecompartment) - as of MY 2003 (All Models) and the cowl panel. Refer to 66 44 19 Removing and installingcowl panel cover - as of MY 2003 (All Models) .

2005 Porsche Cayenne2003-2008 BRAKES Brakes - Hydraulics, Regulator, Booster3. Bleed the vehicle --> 470107 Bleeding the brake system - chapter on "bleeding".4. Calibrate the pressure sensor with the Porsche System Tester.