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I recently replaced the coolant pipes in my car. I needed to do the job myself because there was simply no way I was going to shell out anywhere from $1500 to $3500 in labor to have it done by the dealership or an independent shop. Plus, having read about the job, I knew they would be tearing through a ton of stuff and I really feared the "oh, it also needs this" scam. I did a LOT of research on the various forums before undertaking this job. Reading and printing out anything I thought was useful information. I would highly encourage anyone reading this to do the same. Fortunately, I was not in the position that the pipes simply failed and dumped all of the coolant. I just had a semi-slow leak… dropping about a gallon of coolant every two to three weeks. So, I had time to order the parts and prepare. Prior to doing this the most complicated thing I had done myself was change the oil, replacing the brake pads and swapping out some plastic bits in the car. I had absolutely no prior mechanic experience whatsoever. However, I do work in IT, and am by nature a very technical person (I'm sure every mechanic reading this just rolled their eyes). My job is troubleshooting very complex problems on very large networks, and I think that experience probably lent itself to a successful outcome here. I'm also patient, and that is critical to getting this job done. I will say that I now have a much greater appreciation for mechanics and their skill set. This was hard. I want to caution anyone reading this that this is a BIG job and it will take a long time. My goal in writing this is so that my fellow Cayenne owners can be spared a lot of the mistakes I made and be better prepared than I was. I will say I am relieved to have this done. I feel a ton better about my car now that I don't need to worry as much about some catastrophic failure hitting me unexpectedly. One rule that I really appreciated was to only place metal on metal when working (until you actually get to removing the pipes). This prevents you from breaking plastic or tearing rubber with something metal. Trust me, pay attention to that rule. I am breaking this down into tasks, because I think it's easier to follow that way. This is how I did it. I am sure there are other ways that may even be easier, but this worked for me and my schedule. I ended up working 4-6 hours at a stretch in the garage with breaks every couple of hours. Step 1: Contribute to this forum I have absolutely no affiliation with this forum whatsoever other than I am a contributing member. The advice on this forum has personally saved me thousands of dollars, and being in IT I know the time and money it takes to run a site like this. So, contribute to the cause. However, there is a second reason to contribute, and that's to get the Porsche TSBs. The TSB for this job contains some diagrams that give you a better idea how all the replacement parts go in to place, and I thought that was handy to have. As an aside, I searched some other issues in the TSBs and found answers to some things the dealership didn't even know… such as there being a $33 replacement latch for my armrest. They wanted to sell me a whole new armrest for $750. Step 2: Obtain the Parts I looked around on the Internet and called some local sources and found a dealership that provided the parts for $550, and that included two gallons of coolant shipped to my door. To me, that was a fair price, and when I received the parts I really thought it was a fair price... there's a lot of quality stuff in there. I'm sure there may be cheaper 3rd party sources. I would just be sure they include all gaskets and such that don't necessarily need to be replaced, but should be replaced if you're tearing everything apart. Once you get the parts, pull them out of the box and examine them. Look at the pics in the forum and look at the TSBs. Get a feel for what you are replacing. Step 3: Verify you have the tools I found the following tools very handy to have, and frankly, necessary. I suggest going to your local auto parts store for most of them and get mechanic grade tools. Socket Wrench 3" Socket Extension 6" Socket Extension Metric Socket Set Torx Socket Set (think of this as a "male" Torx Socket set, you will need #27 & #40) E-Torx Socket Set (think of this a "female" Torx Socket set) Screwdriver that accepts interchangeable bits (there are times this is easier than a socket wrench) Torx Bit Set (Specifically you need a #27 and #40, I just bought a set) Locking Long Nose Pliers (6" is fine, no need for anything bigger) Regular set of pliers Wrench Set (somewhat optional) Real flat head screwdrivers Very long flat head screwdriver (this came in handy a lot) Needle Nose Pliers Small Chisel Set Hammer Tin snips Safety Glasses Mechanics Gloves One of those extension things with a magnet on the end One of those extension things with a mirror on the end WD-40 Some all-purpose grease, like White Lightning Baggies to store the screws in Masking tape/Painters Tape to cover up any exposed openings Old Bath Towels (used to protect the car) Good flashlight Lint free rags Shop Vac Two gallons of distilled water Drain pan (needs to hold 4 gallons) Shop lights A small block of wood, about 2" x 4" x ¾" A radio playing energetic music of your choice Advil and Tylenol Hope and a prayer (optional but doesn't hurt) Step 4: Book the Time I know some people say you can have this job done in less than 8 hours, but being a beginner this took me much longer. If I took out all the time running back and forth to the store for tools and such, and had a guide like the one I am writing, I still think it would have taken 10-12 hours. I ended up removing all of the engine covers on one weekend night, and then doing the actual job the following weekend. I then drove the car for a week with the new pipes and finally put all the engine covers back on over the weekend (I cleaned the covers and the engine thoroughly with a damp rag at the same time to pretty it up a bit). You don't really need to do it that way, but that split the work up a bit. I work in an office in front of a PC all day; I'm not used to working in a hot garage for 8-10 hours at a time... I'm a skinny computer geek : ) When I did the work, I draped some old bath towels over the sides and front of the car to protect it. The last thing I wanted to do was mess up the paint on a zipper or with a dropped tool/screw. Step 5: Remove the Engine Covers There are really two parts to this. You have the decorative covers over the actual engine, and then you have the covers that border the engine. You'll want to remove all of the covers around the border first. There are five of them in total. They all have these little black plastic plugs that you just turn 90 degrees. They should just pop up at that point, but you might have to give them a little lift with a screw driver. While you're removing those covers you might want to pay attention to how they go together and where they slide in to place. You'll also want to remove the windshield washing fluid cap (use the masking tape to cover up the exposed hole) before you remove the cover that surrounds it. Those little things are $4.25 each from the dealership, so try not to lose them. Now you have the three silver looking decorative covers; one on each side of the engine and one towards the front middle with the engine type on it. First, you need to unbolt the two secondary air injection units. Those are the round things with the plastic covers near the back of the engine compartment. You do not need to disconnect them from anything, just unbolt them (three screws each) and then move them off to the side. It might be a good idea to get some labeled baggies to store the screws in. Once those are removed you can get to the side engine covers a little easier. The engine cover in the front middle you just lift off, just work it back and forth a little and it should pop off. Take note that there are four little plugs that fit into holes on the cover itself, you'll need to find them again when replacing it. Now remove the one on the driver's side. It's pretty easy to remove. There are four screws towards the bottom that need to be removed, and then the cover will just come off. The one on the passenger side is a bit different. You have the engine mount right in the middle of things. Assuming you have the tools, you can unscrew the engine mount and get it out of the way. That will let you get to each of the four screws easily on the cover and remove it. I wasn't so lucky here (didn't have the right tools at the time), so I just got the four screws out of the cover and ended up wedging it out. While doing that, the piece of the cover under the engine mount snapped off. I wasn't too concerned about this, because where it snapped is hidden by the engine mount. When I put everything back together I just slid it back and screwed it in. You can't tell at all that it was ever snapped in half. Step 5a: Remove Fuel Pump Fuses You'll want to check your manual (you can also download the manual from this site), but you need to remove a couple of fuses for the fuel pump. Right in front of the driver under the hood there is a small compartment. Remove the cover, and then remove a second cover to expose the fuses. Mine were fuse 14 & 15 for the fuel pump. Store them somewhere safe. Once those are removed, start your car. It will run for a few seconds and die. Congrats, you just removed most of the fuel from the fuel line. I know some people don't disconnect the fuel rail or anything, but to me that's a bad idea. I had a lot of time to try it that way and honestly I'm glad I got it out of the way. Step 6: Disconnect the fuel line The fuel line is near the back center, it's just one tube running to the fuel rail. You'll disconnect it by using a wrench and a pair of pliers. You're unscrewing the part on the left (the thin part) from the part on the right (the wide part) which shouldn't turn as it is part of that tube. Once unscrewed, the fuel rail is only connected to the manifold. A little residual fuel might leak out, so you might want to have a rag handy to wipe it up with. Use masking tape to cover up any exposed holes. It wouldn't be a bad idea to disconnect the batteries now either. I didn't, but that was probably stupid. Step 7: Remove the Y-Pipe that goes to the Throttle Body This plastic Y-Pipe is right up front so it's very easy to get to. There are two flexible pipes on either side you need to remove first; just use a screwdriver to loosen the two clamps on each of them and you should be able to compress them enough to remove them. The Y-Pipe itself is attached to the throttle body via two long, plastic bolts. They have a screw head on them but they are not screws, they're more of a key. You just turn them a bit to line the key at the bottom (use a flashlight and you'll see it move as you turn it with the screwdriver) with the slot. When it's lined up, use a pair of needle nose pillars to lift it straight out. It's plastic and may be brittle, so be a little careful. You will need to remove an electric connection to the throttle body in order to get to one of them. There is a tube connected to the bottom of this y-pipe, so you can't just lift it out. It has some give to it, but not a lot… just enough to get your hand under there once you pull the y-pipe off the throttle body. You have to press the buttons on each side of the tube in order to get it off the y-pipe. Step 8: Remove Emission Tubes & Electrical Connections from Throttle Body There are two emission tubes crossing the throttle body, Porsche refers to them as "vent tubes." I know this because one snapped in half when I removed it, and the dang thing was $130 to replace. To remove them, you just need to press the clips at either side of the end of the tube together and then pull it straight out. I don't think mine had ever been removed, and in retrospect a bit of WD-40 used sparingly here might have been a good idea. I think I used too much force and that's why the small one snapped. I have read that some people have replaced this broken tube with a more generic tube from a hardware store. I just spent the $130 and did it right. There is a third tube connected to the throttle body, you just need to remove that one end of it. You will also have two electrical connections to remove. One you had to remove to get the y-pipe off in the previous step. Just remove the second one and then you're done. Step 9: Remove the Throttle Body The throttle body is connected to the manifold via four bolts. Remove those four bolts and it will come off. You sort of have to wiggle it out because of that thin metal bracket that's holding it there, but it will come out easy enough. Some people take this opportunity to clean it. You'll probably see some gunk on the back side of it on the inside. Step 9: Remove the Electrical Connections to the Fuel Injectors There are eight fuel injectors connected between the fuel rail and intake manifold. Mine were blue plastic, and there is an electrical connection running to each of them. There is a metal clip at the bottom that you just need to press up. I placed a flat head screwdriver between this clip and my index finger, and pushed up and pulled at the same time to disconnect it. Once you remove one you'll get the trick and the rest will come right off. Step 10: Remove the Intake Manifold with Fuel Rail Attached I know a lot of people have different ideas here, some people want to remove the fuel rail independently, and that was the first way I tried it. In retrospect, it's much easier to just leave it attached. There are four screws that hold the fuel rail to the intake manifold. I would recommend leaving these alone, especially since the one at the back on the passenger side is nearly impossible to get to. These screws are $6+ each… I know because I lost one. :P There are 10 bolts that need to be undone to remove the manifold. They don't come all the way out, they'll stay attached to the manifold. Once you loosen them enough they sort of come free and wiggle around. The one at the back on the passenger side was a bear to get to. I ended up placing the Torx Socket bit on top of it using the magnetic extension thing. I then put the 3" extension on top of it, and finally attached my socket wrench to it. I kind of built it all up I guess. I then went really, really slowly and loosened it up. Once loose, make sure to vacuum up any debris on the engine. When you pull the intake manifold off you will have eight gaping holes right down to your cylinders, you don't want anything falling in there. You can now scoot it forward a bit to get to the tubes you will need to disconnect. There are two tubes at the back of the manifold… a firm one and a flexible one. The firm one is just like the one under the y-pipe, and is easy enough to remove IF you can get enough pressure on the connector. The flexible one was just kind of stuck on mine and I left it on. You kind of have to scoot the manifold forward and angle it out, but it will come out with the fuel rail attached. You may have to remove some tubes and such from their guides or brackets. That flexible tube was long enough that I just put the whole thing on the driver's side of my engine and left it there. It didn't seem to be sitting on anything that couldn't support it. I'm sure it can be removed, but at this point in the job I was tired, hot, and just wanted to keep going. Once off, IMMEDIATELY cover up the exposed intake holes with long strips of tape. Cover them completely, and make sure they STAY COVERED. Shine a flashlight in each hole first to make sure nothing fell down there. If so, get it out as delicately as possible. Vacuum up any other debris you see. You can now see the infamous coolant pipes. Step 11: Assessment At this point, you can see the coolant pipes and should be ready for the meat of this repair. The starter is right there too… right under the leaking pipes. Brilliant, isn't it? This may not be true for you, but I had an AMAZING amount of debris in here… honestly looked like a bird had built a nest. I have no idea how it all got in there, but some where at some point tons of debris got in here, and now it was all soaked in coolant. I think my coolant leaking may have been mitigated because the wet debris probably acted as a mud and sealed everything up a bit. I vacuumed it up with a shop vac prepped for a wet cleanup. Now you need to decide if you will see this repair through or not. Once the next step is taken, there is no going back, and honestly the toughest part of this job by far is getting the old pipes out. Step 12: Drain the Remaining Coolant Your first goal is removing as much coolant from the car as you can. On the V8's, there is a drain plug at the bottom of the car, but on the turbo's you won't have one. That drain plug required an allen bit that was larger than I had on hand or could even find at a hardware store. Honestly, in retrospect I wouldn't have even bothered locating it. I'm sure there's a pipe down there you could remove, but I didn't waste time looking for. I took a tip I found on a forum, and drilled a hole right in the middle of the center coolant pipe (of three) and used a siphon with a hand pump to drain out every bit I could. I repeated this process on the larger lower pipe. DO NOT SIPHON BY USING YOUR MOUTH. Coolant is dangerous, nasty stuff. Make sure there are no animals or kids around while you are doing this. WEAR SAFETY GLASSES AT ALL TIMES! Doing it this way you're going to spill a lot of coolant, but it is what it is… they've been leaking all over everything anyway. I used my shop vac to vacuum up anything I could that escaped the siphon. I've also read of people renting professional vacuum pumps to suck it all out, but again, that's more complicated than it needs to be. I did some research, and coolant is not currently controlled by the EPA for disposal, and it can't be recycled. The unofficial advice I got was to dump it in the woods and douse the area with a hose for a bit. Do not dump it down the drain or dump it where animals could readily drink it. Don't dump it in a stream. Presumably it breaks down fast enough on the ground that there isn't a long lasting effect. Step 13: Remove the Three Upper Coolant Pipes The first pipe you need to remove is the long skinny pipe with three connectors. This one is easy enough to remove, and you should have a replacement as part of the kit. One of the connectors broke off in the hole, and I had to very carefully remove the pieces. Relatively speaking this was easy compared to the rest. There is a compression ring that needs to be removed for the connection at the back of the engine, use the locking pliers to do that. Cover up the exposed holes with masking tape. You now have to remove the three upper coolant pipes. There is a bracket at the back of the engine holding the three pipes. There are also two clips attached (you'll be looking at the back side of them) to that bracket that just support a hose at the back (just has electrical connections in it, and it's probably already split so you don't have to be super careful). Pinch the connectors with a pair of needle nose pliers and they'll come off. You now have to remove three bolts from it to remove the upper half of that bracket. I removed two of them but couldn't get to the third without snapping the thing in half. Porsche was kind enough to provide a new one in the kit so I wasn't worried about it. You will now see three rubber hoses attached to the plastic pipes. They are held on to them with compression rings. Use the locking pliers on the rings to loosen them (they need to be squeezed together to loosen) and slip them back over the pipes. I did one at a time, completely removing the ring and setting it off to the side for safety. The locking pliers really excelled here. When using them, attempt to come at the ring from the top instead of the side, the grooves on the pliers will then secure the ring quite nicely. You might have to adjust the pliers a couple of time to get the right amount of the compression for the ring to move freely. With those ends free, I used the shop vac to suck out a lot more coolant. Once done, cover up the exposed holes with masking tape. Once those three ends are free, you'll need to free up the other ends. Here's the deal, they are probably going to break when you try to remove them, and probably going to snap off at the spot where they connect to the coolant reservoir. I twisted and pulled and sure enough, they snapped off. You can remove the lid of the coolant reservoir by removing several screws, a small aluminum pipe on top, and the rubber pipes towards the front of the car. The small aluminum pipe has a single screw that needs to be removed. There is probably a lot of corrosion here so you may need to use a flat head screwdriver to pry it out. Be careful, it's flexible enough to come out and get out of the way but just barely. There is a compression ring on each of the rubber pipes that is easy enough to get to, just loosen and slide it down the pipe. Suck out any coolant and cover the exposed pipes with masking tape. Once you have that lid out, you'll see the remaining plastic bits in the holes. It's difficult to move, but those plastic bits are just in there with pressure, they aren't glued or anything. I used a small chisel and the hammer to break them out. As I got to the o-rings I pulled on those with needle nose pliers and in one instance the whole chunk came out. I also used a lot of WD-40 to work everything out. What you don't want to do is take any risk of chiseling into the metal of the lid, so be careful. This is all about removing the plastic material. Each bit you remove gets you one step closer to freeing up enough pressure to get the remaining bit out. Once it's all clean, leave it off to the side while removing the big pipe. Step 14: Removing The Big Pipe This one is tough. Make sure you're rested, well fed, and cooled down a bit. If you're aggravated already, walk away and relax a bit. You will need to break this pipe into two pieces. I used a boring bit to drill a big hole in the top, and then used tin snips to cut chunks out until I got it in two parts. Again, I used a shop vac to suck out any remaining coolant as I went along. Really, anything will work… you could even use a chisel to break it out. It's coming out one way or the other, no need to be pretty about it. Once it's in two pieces, you can probably rotate the two halves apart. Use WD-40 generously on the ends first though, and give it a bit to work in there. Regardless, when I went to pull out the two ends, they ended up snapping off… leaving their end pieces in the hole. If you read through the three forums, different people use different techniques to try and avoid this with mixed results. This is the worst case scenario though, so lucky for you I fought through it and have plenty of advice. Assuming your pipe broke off as mine did, you will see a metal ring in each end, with black plastic between it and your car. That metal ring was an inner support ring for the original pipe and needs to be removed. This is a violent procedure. IMPORTANT: I cut up some lint free cloths and stuffed one into each end as far as I could so that any material from the following procedure wouldn't go any further. Once done with the procedure below, I vacuumed up anything I could and then removed those cloths. Again, use WD40 a LOT. I sprayed and sprayed as a worked, and I think it helped. READ THIS CAREFULLY: Removing the plastic and metal ring from each end is all about removing material. You are trying to get as much plastic out as possible. If you get the ring out first, great, but it's not 100% necessary. The plastic is what needs to come out, and you need to get it out from all around it. In addition to the plastic, there are two o-rings in there, so they are just adding more friction preventing this from moving. You'll get bits of that out as you work, and that's good. Eventually, you get enough bits out that the rest will just fall out. Use a hammer and chisel to collapse the metal ring on the top and sides as much as possible. I used to the chisel to cut in to it a bit too. Once I got it that far, I switched to the long screwdriver, hammering the end of it into the plastic over, and over, and over again. I pried as much as I could and worked out bits of material. This took a long time, but sometimes you'll get a big chunk out and that will give you renewed hope. Again, this is all about material removal. Keep telling yourself that. Every bit you get out makes this easier. Once you get enough plastic out, you'll see the metal ring move a bit as you work. This is a great sign and you are almost done. Ultimately, you should be able to pry it out with the screwdriver. NOTE: When working you want to work as much towards the metal ring as possible. You want to avoid scraping the inside of the hole where your new pipes will go. I did scrape up mine a bit, it's unavoidable, but regardless my new pipes don't leak. When you go to remove the bits closest to you, you're working somewhat blind and it is hard. This part almost broke me, but I used a mirror to check and recheck my work as I went along. Bright lights help here too. Honestly, I really can't say enough how hard this part was and how long it took in comparison to everything else. It was the part that had me the most worried, but I got through it. Once it's all out, remove the cloths from inside the pipe and vacuum a lot. Now is the time to clean stuff up too, as you're about to put the new pipes in. As a best practice, you should clean up the inside of those holes. I used some steel wool; I know some people used scotch bright or even buffing pads. I didn't go overboard with this; I just want to get any grime out of there. Step 15: Install the New Big Pipe At this point you should be elated. You're through the worst. Installing these pipes are a bit difficult, but not bad. If they are not already on there, put the O-Rings on the small pipe. Use the White Lightning grease or whatever you bought and coat the inside of the hole on the engine and the outside of the pipe. Use it liberally. A bit of WD40 wouldn't hurt either. Press it into the hole at the back of the engine and do your best to get it all the way in. This is where a small block of wood and a hammer come in handy; you can use those to tap it in the rest of the way. Do not put the rubber sleeve on it. For the big pipe, install the o-rings and lube everything up good with the grease, both the hole it goes in and the pipe itself. You will also need to grease up the end the rubber part goes on and the other end of the short pipe that the rubber sleeve will slip over. Place the tightening rings over the rubber sleeve as well. Slide the rubber sleeve as far as it will go over the pipe. Push the pipe into the hole, I found a twisting action worked well. I also used my metal screwdriver against the bottom of the engine bay as a lever to slide it in the rest of the way (it required a lot of pressure). You then need to rotate it to line it up with the short end of the pipe. You'll slide the rubber sleeve over it and then tighten up the two rings. NOTE: Be sure to rotate the rings as far down as possible so that the screw does not interfere with the three pipes you're about to place on top of it. The new big pipe should be in place, and you're now done with the hardest part of this job. Step 16: Install the Three Pipes You'll want to put the lid back on the coolant reservoir (replacing the seals Porsche included with the kit), reattach the pipes and tighten up the screws. DO NOT OVERTIGHTEN THE SCREWS. I snapped one clean off. Make sure they're tight, but don't put all your muscle into it. Once on, you are ready to slide those pipes in. You do not need to put the lower bracket at the back on first; I did it after installing the pipes. Again, make sure everything is lubed up well so that any points of friction are well covered. Slide the pipes in. I used by long screwdriver again as a lever to apply the necessary pressure. On both these pipes and the big pipe it looked like I could have gone another 16th of an inch, but nothing leaks so I guess it was far enough. Put the bracket on at the back before you attach the hoses. You'll use your locking pliers again to attach the compression rings. With the bracket in place it is obvious how far up the hoses go. You'll put the upper bracket on, using the spacers for the screws and screwing it down tight. Don't forget to attach the two brackets that hold that electrical cable in place. Not a big deal if you do forget. Step 17: Install Final Pipe Now install that skinny pipe. This one is easy. Don't forget about the small compression ring that goes at the far end. Everything else just clips in. Step 18: Assess Your Work Look over everything and make sure it all looks right. At this point you should have a sealed coolant system. Check all your connections and make sure everything is solid. At this point you're home free, and you should be feeling pretty darn good. Step 19: Fill Up Coolant I use a 50/50 water to coolant ratio… so I mixed everything up with what I had and filled up the coolant tank. Once it was full, I left it overnight and checked in the morning for any fresh coolant. I was totally beat from a long day of working on it and thought putting everything back together fresh in the morning was a good idea. Step 20: Put Everything Back Together You tore it apart, now put it back together. I cleaned everything as I went, so now my engine looks great and I think that's a good idea. You don't need to go overboard, just use some lightly damp, lint free rags and wipe everything down. Porsche should have also provided new seals that go on the bottom of the intake manifold. I replaced mine dutifully, and I am glad I did. The old ones just looked worn out, no way they weren't leaking. Putting everything together is pretty straightforward once you've taken it apart. Just be careful and make sure you get all electrical connections and hoses in back on securely and in the right places (hard to mess that up). Also make sure you remove every bit of masking tape as you go. Final Thoughts I am very, very glad I did this project for two reasons. One, it saved me a ton of money and two, I now know tons more about the engine. Doing this project means I could replace my fuel injectors, spark plugs, injection coils and a host of other things when and if I have to. I know where the throttle body is, and if it's sticking I know where to go to clean it. If I need to replace the starter, I know where it is and how to get to it. I can now take my car on trips without fear of a massive coolant leak. This was the last "major" Cayenne defect for me that needed to be fixed. The water pump & drive shaft were already replaced. With 116,000 miles, I have quite a bit of faith in my car not having a catastrophic failure (knock on wood). At the end of the day, I'm pretty proud of myself for getting this all accomplished, and I hope I've saved some other poor soul a ton of time by writing all of this down. If it does help you out, please reply to this post and let me know.

Today I did front final drive gear oil change. This DIY will show you how I did it. Since I had a hard time to access the drain plug, I removed fill plug and used a pump to suck out the final drive oil. Worked really well, and helped avoid messy drain, which puts oil onto the lower axle carrier frame too. FSM calls for change quantity of 0.42L, and I managed to remove about that much from the drive, so I feel confident I got it all. Used empty oil can go suck old oil into it, and another empty oil can to put same amount of new oil it, making sure I fill with what I removed. I actually filled the new oil can with maybe 1/4" more oil, to accommodate for some oil that pump cannot take out of can, and some oil left in tubing. Oil used for change: Mobil Delvac 1 full synthetic gear oil 75W-90 (direct cross reference to Shell TF0951 - factory fill oil) Oil refill quantity: 0.42L (bit less than half a quart) New fill plug part number: N 902 818 02 Fill plug tighten torque: 25.8 ft/lbs Fill plug removal tool: ratchet, extensions (at least 6"), 5mm hex socket, shop towels Look at this DIY before you do the change. Make sure you have all materials and time to do it. Expect about an hour to hour and a half to complete. Let us know if you have comments. Thank you.

This DIY tutorial covers how to remove the intake manifold on the 3.6L V6 Cayenne. Removing the intake manifold gives you access to several parts of the engine that you may need to service. Disclaimer: Perform at your own risk. This is for reference only, I am not responsible for any damage/injuries that may occur from this procedure. Please do not attempt if you are not comfortable with doing work on your car or working around the fuel system. Work in a well ventilated area as you will be releasing a small amount of gas and fumes. Difficulty: 5/10 Estimated Time: ~2 hours If you’re getting a Durametric error code P0674, you likely have a bad PCV valve that needs to be replaced. An easy way to test a bad PCV valve is to unscrew the oil fill cap on the engine while it is idling. If you feel suction on the cap and/or the idle fluctuates once the cap is removed then your PCV valve is bad. The PCV valve is built into the valve cover so your options are to buy a whole new valve cover assembly (95510513500- ~$347) or buy just the PCV membrane (aftermarket $20-25) and replace it in your existing valve cover. To get access to the valve cover, you will need to follow this DIY article to remove the intake manifold first. Other reasons to remove the intake manifold are to service your fuel injectors or to make it much easier to replace the thermostat. The thermostat can be changed without removing the intake manifold (I did it twice), however you basically need to be a contortionist to reach the bolts to remove housing and you will scrape some knuckles along the way. Tools Needed: -Flathead screwdriver -Assortment of torx bits (T20, T25, T30, 6” long T30) -Pliers -Torque Wrench -3/8” ratchet set with various extensions and a universal joint -1 1/16” Deep socket -10mm Triple Square Spline Bit -Crescent Wrench -9/16” Open End Wrench -Dental pick Parts Needed: -Brake Booster Vacuum Hose- 95535557941 (your existing hose is probably brittle and will likely crack from removing it, I recommend getting a new one) -Lower Fuel Injector Seal Kit (3X) - 95511091000 (existing seals may be brittle and once you have removed the intake manifold, they may not seal properly upon reinstallation, I recommend getting new ones, need 3 sets) Procedure: First start by removing the plastic covers surrounding the engine. Using a flathead screwdriver, remove the quarter turn plastic trim fasteners. Rotate them in either direction by 90 degrees and pop them out. Be ready to catch them as sometimes they like to jump out. Next you will need to remove the 2 torx screws on either side of the engine cover with a T25 bit and the screw under the windshield washer reservoir cap with a T20 bit. Remove the oil fill cap and front engine cover by pulling straight up. They are held on by friction rings around a stud so pulling straight up will release it. Now that you have the covers removed, it’s time to remove the intake filter box and intake piping. Using your T25 torx bit, rotate the 2 screws until the dot on the screwhead lines up with the lower indication on the filter cover. Now gently use your pliers to pull them straight out. With your flathead screwdriver, pop up the two clips to release the filter housing. Pivot the filter house towards the passenger side of the car and remove it. Remove the engine air filter as well. Next, remove the wiring harness from the MAF sensor located in the middle of the intake piping. Loosen the clamp around the intake piping on the throttle body and gently work the intake piping back and forth until it releases from the throttle body. Remove the top bolt on the engine lift bracket and loosen the lower bolt with your M10 triple square bit. Then pivot the bracket towards the front of the car. Remove the bolt next to the throttle body with your M10 triple square bit. Then unplug the wire harness from the throttle body. Remove the top bolt from the bracket on the passenger side of the engine with your M10 triple square bit. Remove the vacuum lines from the intake manifold on the passenger side of the engine. One hose requires pliers to open the hose clamp, the other can be removed by hand if you squeeze the lock ring around the hose to release it. Next, from the passenger side, reach your hand around to the back side of the engine. There is a vacuum line that goes from the bottom surface of the intake manifold to the brake booster. You will need to pull the vacuum line fitting straight down to pop it out of the intake manifold. I don't have a good picture of it so here is a diagram of it. Pull down on the elbow fitting, not the hose. Also on the back side of the engine just behind the vacuum line you removed there is a bolt that needs to be removed using your M10 triple square bit. You are working blindly so locate the bolt first by feel and guide your bit to the bolt. Remove the 3 screws holding the actuator with a T25 torx bit. Slowly pull it straight out towards the front of the car. There is an actuator arm that attaches to a shaft on the passenger side of the part. Once you have enough clearance to reach your finger in there, you need to slide the arm off the shaft as you pull the entire actuator off. Then disconnect the vacuum hose from the actuator. Now pull the coolant hoses out of their holder in the intake manifold and push it towards the driver side of the car. There is a T25 torx screw that attaches this water hose bracket near the back of the intake manifold. The screw is facing up, so you need to use your T25 torx bit and get creative with removing that screw. I used a crescent wrench to turn the torx bit while holding the torx bit in place with my other hand. With the water hose bracket free, slide the water hose bracket towards the front of the car to release it from the intake manifold. This bracket has a keyhole slot that will release once it's slid forward. Remove the oil dipstick tube bracket with a T25 torx bit. Just push it out of the way once you remove the screw. With your long T30 torx bit, remove the bolt on the intake manifold that was under the actuator. Next, there are 3 blind holes on the driver side of the intake manifold. You need to use your long T30 torx bit to loosen the screws inside those holes. Those 3 screws are captive screws so they will not come out. There are 3 bolts below the intake runners. They need to be removed with your M10 triple square bit. This is where your universal joint will come in handy. The bolt near the rear of the engine required me to use my u-joint with various entensions to acess. At this point, you will hear gas leaking out. Since you have released the pressure from the lower fuel rail to the lower fuel injectors, the pressurized gas in the rail will leak out. Make sure you are working in a well ventilated area. From the driver side of the car, reach behind the engine to remove the wire harness from the fuel pressure sensor. Using your 1 1/16” deep socket, unscrew and remove the fuel pressure sensor. Using your 9/16” open wrench, unscrew the nut that connects the metal fuel line running from the lower fuel rail. The slimmer your wrench the better. My crescent wrench did not fit here. Now that the intake manifold is completely unbolted, you can start to wiggle it free. You will need to lift the manifold up from the passenger side and pivot it up towards the driver side. You will need to wiggle the lower fuel rail loose to release the metal fuel line you just unscrewed the nut from. It is a flare fitting that pushes into the upper fuel rail assembly. Be gentle here as you don’t want to bend the fuel rail. Once the metal fuel line is free from the upper assembly, you can remove the intake manifold as described above by lifting up from the passenger side first to pivot it off. At this point, you have access to the fuel injectors if you need to service them, the thermostat housing and the valve cover. Unbolting the valve cover is straight forward from here if you need to replace the PCV valve, etc. The fuel injector seal kit comes with a rubber o-ring, Teflon o-ring, Teflon sleeve and metal clip. At the bare minimum you should replace the rubber o-ring and Teflon o-ring. Use a dental pick to remove the old o-rings. These 2 parts are the wear surface when you remove/reinstall the intake manifold and are prone to fail if you re-use them. Trust me, I learned the hard way. To install the intake manifold, reverse the steps above. Take care in sliding the lower fuel rail back onto the lower fuel injectors and lining up the metal fuel line back into the flare fitting. I found it was easier to pull the lower fuel line out of the manifold to line the flare fitting up first, then pushing it into place in the intake manifold. You want to apply even pressure on the surface as you tighten all 7 of the bolts down on the driver side. Torque the 3 triple square bolts evenly to 6 ft lbs, torque angle 90 degrees, then a final torque of 22 ft lbs. The bolts holding the engine lift bracket are 17 ft lbs, the other triple square bolts holding the manifold on the head are 15 ft lbs. Once you get it all back together, turn the key to the ON then START position without your foot on the brake. This will run the fuel pumps to build pressure back up in the fuel rail. I removed the key and repeated 2-3 times to get the fuel pressure up. The first time you restart, it may take a couple seconds to fire up due to the fuel pressure needing to build back up. If you replaced your PCV valve, it may idle rough as the ECU needs to remap since it adapted to a leaking PCV valve over time. If you did not replace the fuel injector seals and smell gas/hear it leaking after shutting off the engine, then your seals failed and you need to repeat the procedure and replace those seals.

So i have had this annoying display with my 2004 CTT that my rear glass is open, when it really isn't. It would sometimes go away but could come back if i hit a large enough bump in the road. The particular annoyance happens every time you stop and start, it will beep at you again....OR the fact that you cannot lock and arm the car with the glass "open." Anyways this is how you can potentially resolve that issue: Tools needed: Your hands Adjustable wrench Step 1: Open the glass and remove the small plastic cover on the glass side as shown. You will want to get your fingers behind the TOP first, then pull the entire cover free. the clip are pretty strong, so it takes some force, just work it free evenly and slowly. Step 2: Now you have access to the latch on the left (metal hoop). You will want to use the adjustable to loosen the latch or nut. Once it's loose, you can turn it either in or out to make the adjustment needed. For me, i had to turn it OUT, loosening the latch. My guess is the rubber seal has become stiffer over the years, so it was pulling the latch away from the sensor. Reinstall plastic once you get the positioning correct and enjoy no more annoying messages or alarms every time you stop at a light.

Replacing Switch on Transmission for Reverse Lights / Back-Up Lights Replacement Parts: 1. SWITCH, BACK-UP, part number 996.606.103.01 (This is the correct part number for my '99 911 Carrera 4. Check with your local dealer to confirm the correct part number for your car.) (Cost at my dealership on 21 Oct 2005: $8.16 + tax) Tools Required: 1. 19mm box-end wrench 2. Medium-sized flat-blade screwdriver Procedure: 1. If you are working under your pickup or SUV (and the wheels are still on) and the jack breaks or your stands slip, at least there is enough space for your body under that vehicle when it comes crashing down. Under your Porsche, there is no room for you unless you are only 3.6 inches thick. If the jack fails or the stands slip and the car falls, you will either die, or at least be crapping in a bag for the rest of your life. So lift the rear of the car up in a very SAFE and STABLE manner. I recommend the use of ramps, as shown in the picture below. Note how the front wheels are chocked, the ramps are super-sturdy and have stop blocks at the ends, and the car is in gear with the handbrake very tightly engaged. 2. Locate the reversing light switch on the portion of the transmission that is furthest forward in the vehicle. The switch is mounted in a hole in the transmission housing that faces directly up, and has a two-wire snap-on connector. (This is the location for a '99 911 Carrera 4 with the 6-speed Getrag transmission; your car may be different. Regardless, it shouldn't be hard to find.) 3. Using a medium-sized flat-blade screwdriver, pry the snap retainer of the wiring connector open slightly so that the connector will come off. Note that you will have to pry the connector so the plug can slide out, while at the same time applying pressure to the plug to push it out. The green rubber portion of the connector is to keep water out of the connection area, but it also adds some friction to the connection. You won't have to push too hard, so just make sure you're moving the snap retainer out of the way enough. 4. With the connector removed, drop your 19 mm box-end wrench over the switch from above. There should be plenty of room and it's easy to access. The threads are standard, so lefty-loosey righty-tighty. You should only have to turn the switch with the wrench about 1/12th of a turn at the most to break it loose, it should come the rest of the way out very easily with your fingers. When installing the new switch, be sure the switch body is aligned with the axis of the hole! The switch body material is either aluminum or magnesium, so be careful not to cross-thread the new switch upon installation. The new switch should screw all the way in VERY easily with your fingers. Apply a small amount of torque to the switch with the wrench when bottomed out. DO NOT OVERTIGHTEN the switch, you wouldn't want to strip the threads of the new switch. There is no seal ring between the switch and the transmission housing. When fully seated, the barb/emboss on the white plastic part of the switch (that the snap retainer snaps onto) should be facing the front of the car, approximately. (See photo below.) 5. Reinstall the wiring connector, be sure to push it all the way in so no green rubber boot is visible, and you hear the *click* of the snap retainer. Cheers! You've just saved yourself over $100...

There have a been a few occurances of the cabrio top not fully completing the cycle, or simply refusing to open or close. If the hand brake light is on, very likely it is a low hydraulic fluid condition. The work below shows step by step how to add the fluid to the system. Tools needed: 5 mm allen wrench Flat screwdriver Children medicine syringe with small hose 1 Bottle of hydraulic fluid. Porsche is the recommended, I have used John Deere below with no problems after 4 weeks of filling: The steps for the process: 1. Open the top partially to the position shown 2. Pull the cables that the keep the rearmost part of the top secured to the car. One cable per side, the separate the cable from the connection in the car. 3. Let top move towards the close postion and move it out of the way. 4. Use a flat screw driver to remove the 4 plugs that keep the rear carpet in place. Remove the carpet, starting at the top as shown 5. Not a bad time to vacuum this piece while it is out. If you have kids, remove the lollipop sticks :P The work area will look like this: 6. This is the system pump you are looking for. Notice the screw where the Allen wrench will go to. Remove the screw, and keep a magnet pick up tool nearby if it fall down. 7. Use a flashlight on the oppsite side and shine direcly to the reservior. You will be able to clearly see the level and the gap to full. The fullmark is in the front below the screw removed. 8. To fill the top, use the syringe filled with fluid and insert the hose into the hole below. WARNING, the brass washer may fall off if you are not carefull, you can remove it or leave it and chance it. It probably won't move 9. Replace the screw, using fingers first to get it started. Take your time, will not be easy the first round. Finalize withe Allen wrench 10. Replace the carpet (did you clean it?) and the secure it with the plugs. Move the top back in place and secure the cables to the car. Open and close the top a few times. Enjoy the open air And remember, nothing races like a Porsche, but nothing runs like a deer