2006 Porsche Cayenne

2003-2008 BRAKES Anti-Lock Brake System (ABS)

2003-2008 BRAKES

Anti-Lock Brake System (ABS)

45 IN INFORMATION ON PSM - AS OF MY 2003 (CAYENNE TIP, CAYENNE S

TIP, CAYENNE TURBO, CAYENNE TURBO S)
INFORMATION ON PSM

PSM is an active control system to stabilize the vehicle at the limit of driving dynamics. Sensors continuously
determine:

 Vehicle speed
 Direction of travel (steering angle)
 Transverse acceleration
 Longitudinal acceleration
 Rate of turn

NOTE:  The PSM (Porsche Stability Management) is automatically ready/switched

on after each engine start.

Off-road PSM

When the Low Range/Off-road programmer is switched on, an off-road PSM specially adapted for off-road
terrain to improve traction is automatically activated. At speeds below 35 km/h, the off-road PSM reacts later in
the case of under or oversteering and improves the steering control.

Switching off PSM

Press the PSM switch. The PSM switches off after a short delay.

When the PSM is off, the PSM OFF warning light in the instrument panel and the indicator light in the switch
are lit.

 When braking, the vehicle is also stabilized when the PSM is switched off!
 One-sided wheel spin is also prevented when the PSM is switched off!
 On Tiptronic vehicles, the slip upshift function is switched off when PSM is switched off . Refer to
Characteristic features of Tiptronic vehicles (slip upshift).

The PSM should always be switched on for normal driving.

In the following exceptional cases, it can be advantageous to switch off the PSM temporarily:

- On a loose surface and in deep snow

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- When rocking the vehicle free

- When using snow chains

- On extremely difficult terrain (if one or more wheels have little or no road grip - engine performance is
reduced)

Switching PSM back on

Press the PSM switch. The PSM switches on after a short delay.

Characteristic features of Tiptronic vehicles (slip upshift)

 When a maximum permissible speed difference between front and rear axle is exceeded, the integrated
slip monitoring shifts into the next highest gear. This increases the driving stability on slippery roads.
 When PSM is switched off, the slip monitoring (slip upshift function) is also switched off. In this way,
the Tiptronic enables an active sporty driving style even when the friction coefficient is low as is the case
with manual transmission vehicles.

45 IN INFORMATION ON PSM - AS OF MY 2003 (CAYENNE MAN, CAYENNE

S MAN)
INFORMATION ON PSM

PSM is an active control system to stabilize the vehicle at the limit of driving dynamics. Sensors continuously
determine:

 Vehicle speed
 Direction of travel (steering angle)
 Transverse acceleration
 Longitudinal acceleration
 Rate of turn

NOTE:  The PSM (Porsche Stability Management) is automatically ready/switched

on after each engine start.

Off-road PSM

When the Low Range/Off-road programmer is switched on, an off-road PSM specially adapted for off-road
terrain to improve traction is automatically activated. At speeds below 35 km/h, the off-road PSM reacts later in
the case of under or oversteering and improves the steering control.

Switching off PSM

Press the PSM switch. The PSM switches off after a short delay.
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When the PSM is off, the PSM OFF warning light in the instrument panel and the indicator light in the switch
are lit.

 When braking, the vehicle is also stabilized when the PSM is switched off!
 One-sided wheel spin is also prevented when the PSM is switched off!
 On Tiptronic vehicles, the slip upshift function is switched off when PSM is switched off . Refer to
Characteristic features of Tiptronic vehicles (slip upshift).

The PSM should always be switched on for normal driving.

In the following exceptional cases, it can be advantageous to switch off the PSM temporarily:

- On a loose surface and in deep snow

- When rocking the vehicle free

- When using snow chains

- On extremely difficult terrain (if one or more wheels have little or no road grip - engine performance is
reduced)

Switching PSM back on

Press the PSM switch. The PSM switches on after a short delay.

45 IN INFORMATION ON PSM - AS OF MY 2003 (CAYENNE S TIO TITAN)

INFORMATION ON PSM

PSM is an active control system to stabilize the vehicle at the limit of driving dynamics. Sensors continuously
determine:

 Vehicle speed
 Direction of travel (steering angle)
 Transverse acceleration
 Longitudinal acceleration
 Rate of turn

NOTE:  The PSM (Porsche Stability Management) is automatically ready/switched

on after each engine start.

45 11 19 REMOVING AND INSTALLING SPEED SENSOR - AS OF MY 2003

(ALL MODELS EXCEPT CAYENNE S TIO TITAN)

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PRELIMINARY WORK

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) .

REMOVING SPEED SENSOR

Installation Location:

Fig. 1: Speed sensor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

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Fig. 2: Installation location speed sensor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. At the front, turn the steering so far that the speed sensor is made more easily accessible. The wheel in the
rear does not need to be removed.

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Fig. 3: Speed sensor connector

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Disconnect speed sensor connector.

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Fig. 4: Speed sensor fastener

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Unscrew fastening screws and remove speed sensor.

INSTALLING SPEED SENSOR

NOTE:  The speed sensor must be inserted using Optitemp (Optitemp LG2, 25-ml
spray can available under Part No. 000.043.204.21).

 The bore for mounting the speed sensor must be free of dirt.

 Observe correct tightening torques.

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1. Position speed sensor in the installation position and screw down.

2. Plug in connector.

SUBSEQUENT WORK

Lower 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) .

45 30 19 REMOVING AND INSTALLING HYDRAULIC UNIT - AS OF MY 2003

(ALL MODELS EXCEPT CAYENNE S TIO TITAN)
TOOLS

Designation Type Number Explanation

bonnet stay special tool 97040

PRELIMINARY WORK

1. Remove plenum panel cover. Refer to 66 44 19 Removing and installing cowl panel cover - as of MY 2003
(All Models) .

2. Using the bonnet stay 97040 the bonnet can be opened wider for better accessibility of the plenum panel. To
do this, remove the front gas spring and mount the bonnet stay. Refer to 55 31 19 Removing and installing
pneumatic spring - as of MY 2003 (All Models) .

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Fig. 5: Removing DME control module

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Remove the DME control module -arrows- . Refer to 24 70 19 Removing and installing DME control
module - as of MY 2003 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne
Turbo) . See Fig. 5.

REMOVING HYDRAULIC UNIT

NOTE:  When fitting the hydraulic connections, the electric plug connections on
the control units must remain connected as long as possible. This
prevents the plug connections on the hydraulic unit or in the connectors
inside from being splashed with brake fluid or water.

 Any damp connector must be wiped dry before being disconnected from the connector on the hydraulic
unit. If necessary, provide the connector with a suitable protector.

 Brake fluid on electrical contacts (even thinned brake fluid) leads to corrosion and may cause faults in
the system.

 The brake lines must not be bent in the area of the hydraulic unit.

 Clean the interfacing points of the brake lines, but not with cleaning agents.

 Rinse off any brake fluid emerging thoroughly with water.

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The hydraulic unit is installed in the plenum panel on the front right, under the DME control unit. See Fig. 6.

Fig. 6: Hydraulic unit

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 7: Location of hydraulic unit below DME control unit support and ground cable
Courtesy of PORSCHE OF NORTH AMERICA, INC.

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NOTE:  When fitting the hydraulic connections, the electric plug connections on
the control units must remain connected as long as possible. This
prevents the plug connections on the hydraulic unit or in the connectors
inside from being splashed with brake fluid or water.

 Any damp connector must be wiped dry before being disconnected from the connector on the hydraulic
unit. If necessary, provide the connector with a suitable protector.

 Brake fluid on electrical contacts (even thinned brake fluid) leads to corrosion and may cause faults in
the system.

 The brake lines must not be bent in the area of the hydraulic unit.

 Clean the interfacing points of the brake lines, but not with cleaning agents.

 Rinse off any brake fluid emerging thoroughly with water.

1. Release the ground cable -arrow- , unclip the wiring harness and set it aside. See Fig. 7.

Fig. 8: DME control unit support

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Remove the support for the DME control unit -arrow- . See Fig. 8.

3. Remove the housing of the intake air duct. To do so, loosen the two external fastening nuts and the two
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retaining clips in the inside of the air duct.

4. Provide a suitable protector for the control unit connector.

5. Activate the brake pedal by hand using the brake pedal loader, (do not clamp it yet!). Plug the vent hose of
the vent bottle onto the front left and rear left bleeder screw of the brake calliper (2nd fitter required). Open the
bleeder screws until the brake pedal is completely pressed down. Tighten the brake pedal loader and close the
bleeder screws. This will close the central valves of the tandem brake master cylinder so that only a little brake
fluid can flow out of the opened brake system.

6. A sufficient number of cloths should be put under the hydraulic unit to absorb any brake fluid emerging. If
some runs into the plenum panel nonetheless, immediately rinse thoroughly with water.

Fig. 9: Marking lines of hydraulic unit

Courtesy of PORSCHE OF NORTH AMERICA, INC.

7. Mark the lines on the hydraulic unit (color marking, etc.) and remove. Seal the loosened lines with suitable
plugs. See Fig. 9.

8. Pull off the control unit connector from the control unit.

9. Remove the hydraulic unit (a/f 8) and take out of the bracket, upwards.

INSTALLING HYDRAULIC UNIT

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WARNING: Porsche Stability Management does not work without values for the
current brake pressure.

 Danger of personal injury and material damage when the hydraulic

unit is not calibrated.

--> After assembling the hydraulic unit, a static test and a swap test must be carried out with the Porsche System
Tester.

--> After assembly of the brake master cylinder or the hydraulic unit, the pressure sensor must be calibrated
with the Porsche System Tester.

NOTE:  When fitting the hydraulic connections, the electric plug connections on
the control units must remain connected as long as possible. This
prevents the plug connections on the hydraulic unit or in the connectors
inside from being splashed with brake fluid or water.

 Any damp connector must be wiped dry before being disconnected from the connector on the hydraulic
unit. If necessary, provide the connector with a suitable protector.

 Brake fluid on electrical contacts (even thinned brake fluid) leads to corrosion and may cause faults in
the system.

 The brake lines must not be bent in the area of the hydraulic unit.

 Clean the interfacing points of the brake lines, but not with cleaning agents.

 Rinse off any brake fluid emerging thoroughly with water.

NOTE:  Install in reverse order.

 Remove the plugs on the new hydraulic unit after the respective brake line is fitted.

 Pay attention to tightening torques --> 47 TW TIGHTENING TORQUES FOR BRAKE

HYDRAULICS - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN) .

1. Bleed the brake system. To ensure the full function of the brake system, drain approx. 250 ccm brake fluid
from each wheel. Refer to 47 01 07 Bleeding the brake system - as of MY 2003 (All Models Except Cayenne
S TIO Titan) .

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Fig. 10: Porsche System Tester

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Calibrate the pressure sensor with the --> Porsche System Tester . To do this, select menu >> PSM >>
Calibration >> Pressure sensor <<. The security code is displayed in the Porsche System Tester under menu >>
PSM >> Actual values <<. See Fig. 10.

3. The combination sensor (which contains the longitudinal and transverse acceleration sensor) and the steering-
angle sensor must then be calibrated. The procedure for this is described in Step 2.

4. Perform a swap test with the Porsche System Tester. To do this, select menu >> PSM > > Function selection
>> Drive links <<.

NOTE: When replacing the hydraulic unit, the connected control mechanism must be
coded with the Porsche System Tester (running gear and country coding).

 To do this, select menu >> PSM >> Function selection >> Coding << and
the relevant country. Observe the country coding!

5. Code hydraulic unit.

6. Perform a function test. During the test drive, perform at least one ABS control operation, taking the road
conditions into consideration. Read out fault memory. There must not be any stored faults.

45 60 05 INITIALIZING AND CALIBRATING STEERING ANGLE SENSOR - AS

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OF MY 2003 (ALL MODELS)

CHECKING STEERING ANGLE SENSOR

Initialize steering-angle sensor

CAUTION: Increased risk of accident whenever power supply is interrupted. PSM

does not function.

--> The steering-angle sensor must be initialized (taught) whenever the battery is disconnected.

NOTE:  The steering-angle sensor is integrated into the steering column switch
and records the movements of the steering wheel (steering wheel angle)
using light switches. The data is transmitted to the PSM control unit via
the CAN bus.

 During initialization, the steering-angle sensor learns its current position (straight-ahead position).

 The steering-angle sensor must always be initialized if terminal 30 was interrupted (for example, battery
replacement, undervoltage, steering column switch disconnected, relevant fuse removed)!

 Calibration must be performed when working on or carrying out subsequent work on the chassis. This is
described in detail in the next chapter. Refer to 45 60 05 Initializing and calibrating steering angle
sensor - as of MY 2003 (All Models).

 The calibration results in zero point balancing (exactly straight ahead).

 The steering angle sensor is calibrated when first fitted and when any work has been carried out on
steering and chassis. Examples of this would be opening the steering wiring and alterations to toe and
camber.

 Calibration includes initialization.

1. Turn wheels to straight-ahead position.

2. Start engine.

3. From the straight-ahead position, turn steering wheel approx. 20° to the left and 20° to the right (past straight-
ahead position).

4. Drive the vehicle straight ahead for at least one second at a speed of over 4 km/h (2.5 mph).

Following successful initialization, the stored fault code is set to "Not present". The PSM indicator light in the
instrument cluster goes out.

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CAUTION: Increased risk of accident if the battery is disconnected after initializing

and/or the relevant fuse is removed. There must be no undervoltage
during the process.

--> Every time the battery is disconnected, the relevant fuse removed or an undervoltage is present, the steering-
angle sensor must be initialized (taught).

ADJUSTING STEERING ANGLE SENSOR

Calibrating steering-angle sensor

NOTE:  The steering-angle sensor must be recalibrated on the measuring platform

following repairs to or work on the chassis/steering or if the steering-angle
sensor/steering column switch/hydraulic unit is replaced.

 In order to be able to calibrate the steering angle sensor correctly, the vehicle must be on the measuring
platform, the wheel alignment values correct and the steering in the straight-ahead position.

 The security code is displayed in the PIWIS tester under Menu >> PSM >> Actual values.

The steering angle sensor must be calibrated using the menu with the Porsche System Tester under the specified
test conditions:

1. Switch on ignition.

2. Running gear set according to Porsche specifications.

3. Wheels in straight-ahead position and steering wheel horizontal.

4. In the straight-ahead position, the steering wheel must deviate by no more than ± 2.0° from the horizontal
position (steering center position).

5. After successful calibration, the stored fault code is erased from the fault memory. The PSM indicator light in
the instrument cluster goes out.

45 60 19 REMOVING AND INSTALLING STEERING-ANGLE SENSOR - AS

OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN)
GENERAL INFORMATION

The steering-angle sensor is integrated into the steering column switch. See Fig. 12.

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Fig. 11: Steering-angle sensor/steering column switch

Courtesy of PORSCHE OF NORTH AMERICA, INC.

The steering angle is recorded in the contact unit for airbags (spiral spring) -C- . The sensed data is sent from
the electronic unit -E- via the drive CAN bus to various systems (e.g., PSM, corner-sensitive headlight) for
further processing. Replacement of the steering angle sensor requires the steering column switch to be removed.
See Fig. 12.

If faults have been diagnosed on the steering-angle sensor, the steering column switch must be disassembled
into the components -A, B, C, D, E- . See Fig. 12.

It is only permissible to replace the steering-angle sensor as the combination of the components contact unit for
airbag -C- (spiral spring) and electronic unit -E- . See Fig. 12.

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Fig. 12: Steering-angle sensor/steering column switch components

Courtesy of PORSCHE OF NORTH AMERICA, INC.

A - Direction indicator switch

B - GRA switch

C - Contact unit for airbag (spiral spring)

D - Switch for wiper and washer system

E - Electronic unit

REPLACING THE STEERING-ANGLE SENSOR

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Fig. 13: Steering-angle sensor/steering column switch components

Courtesy of PORSCHE OF NORTH AMERICA, INC.

A - Direction indicator switch

B - GRA switch

C - Contact unit for airbag (spiral spring)

D - Switch for wiper and washer system

E - Electronic unit

1. In order to replace the steering angle sensor, the components contact unit for airbag -C- and the electronic
unit -E- must be replaced. Refer to 94 50 19 Removing and installing steering-column switch - as of MY
2003 (All Models) (Removing and installing steering column switch includes disassembling and assembling).
See Fig. 13.

2. Once installed, the steering angle sensor must be calibrated with the Porsche System Tester PSM. Refer to 45
60 05 Initializing and calibrating steering angle sensor - as of MY 2003 (All Models).

45 61 55 REPLACING COMBINATION SENSOR - AS OF MY 2003 (ALL

MODELS)
PRELIMINARY WORK

Preliminary work

NOTE: The combination sensor is located under the center console.

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The functions listed below are integrated into the combination sensor:

 Rate-of-turn sensor

 Lateral acceleration sensor

 Axial acceleration sensor

Installation Location:

Fig. 14: Overview of combination sensor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

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Fig. 15: Combination sensor under the center console (cup holder)
Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Disconnect battery. Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003
(All Models Except Cayenne S TIO Titan) .

2. Remove center console cover and cup holder. Refer to 68 19 19 Removing and installing cover for center
console - as of MY 2003 (All Models) .

3. Remove triggering unit for airbag. Refer to 69 53 19 Removing and installing triggering unit for airbag -
as of MY 2003 (All Models) .

GENERAL WARNING NOTES

Warning notes

CAUTION: Increased risk of accident if combination sensor is uncalibrated or

incorrectly calibrated.

 Possible danger of damage or injury.

--> After installation or replacement of combination sensor, calibrate vehicle with the Piwis tester.

--> Calibration must only be performed with the vehicle >> standing horizontally with the brakes off <<.

REPLACING COMBINATION SENSOR

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Replacing combination sensor

Fig. 16: Separating carpet at combination sensor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Separate the cross bar of the carpet -arrow - . Underneath is the combination sensor. See Fig. 16.

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Fig. 17: Pulling off plug of combination sensor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

First push on the combination sensor connector firmly (makes removal easier!). -arrow- . Lift connector lock
and then remove connector! See Fig. 17.

Replace combination sensor. --> Tightening torque: 8 (6 ftlb.) Nm +/-1 (0.5 ftlb.) Nm .

SUBSEQUENT WORK

Subsequent work

1. Install triggering unit for airbag. Refer to 69 53 19 Removing and installing triggering unit for airbag - as
of MY 2003 (All Models) .

2. Install center console cover. Refer to 68 19 19 Removing and installing cover for center console - as of
MY 2003 (All Models) .

3. Connect the battery. Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003
(All Models Except Cayenne S TIO Titan) .

NOTE: After installation or replacement of combination sensor, calibrate vehicle.

 Calibration must only be performed with the vehicle >> standing

horizontally with the brakes off <<.

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4. Calibrate combination sensor. To do this connect the Piwis tester: Select >> Vehicle Cayenne >> System
PSM >> Actual values menu >> Security code << (at end of list). Note the security code. Quit >> Actual values
menu <<.

5. Select >> Calibration menu <<. Enter security code. Calibrate >> Lateral acceleration sensor << and >>
Axial acceleration sensor << in sequence using the menu.

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