2006 Porsche Cayenne

2003-2008 HVAC Auxiliary Air Conditioning

2003-2008 HVAC

Auxiliary Air Conditioning

88 10 19 REMOVING AND INSTALLING AUXILIARY AIR-CONDITIONING

UNIT - AS OF MY 2003 (ALL MODELS)
TOOLS

Designation Type Number Explanation

mounting pliers for spring commercially 72-1
band clamps, Cayenne hose available tool
connections

PRELIMINARY WORK

Preliminary work

1. Drain engine coolant. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY
2003 (All Models) .

2. Remove rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

REMOVING AUXILIARY AIR-CONDITIONING UNIT

Removing auxiliary air-conditioning unit

NOTE:  For vehicles with four-zone air conditioning (2+2), the auxiliary air-
conditioning unit is located behind the left rear side section cover for the
auxiliary air-conditioning unit.

Installation Location:

Microsoft
Wednesday, September 16, 2009 5:08:54
5:08:49 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 1: Overview of auxiliary air-conditioning unit

Courtesy of PORSCHE OF NORTH AMERICA, INC.

CAUTION: Danger of injury from contact with the refrigerant

--> Observe safety regulations when working with refrigerant. --> 80 AW SAFETY REGULATIONS FOR
EXTRACTION AND FILLING SYSTEMS - AS OF MY 2003 (ALL MODELS) .

1. Remove refrigerant by suction. Refer to 87 03 17 Adding refrigerant and removing by suction - as of MY

2003 (All Models) .

Microsoft
Wednesday, September 16, 2009 5:08:49 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 2: Pulling out the air duct from the air-conditioning unit
Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Press together the air duct from above and pull out of the air-conditioning unit.

Microsoft
Wednesday, September 16, 2009 5:08:49 PM Page 3 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 3: Disconnecting plug connections

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Press the release on the electrical plug -A- -arrow a- and pull off plugs -A- and -B- . See Fig. 3.

Microsoft
Wednesday, September 16, 2009 5:08:49 PM Page 4 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 4: Tilting the auxiliary air-conditioning unit inwards

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Unscrew the fastening screws -1- and tilt the auxiliary air-conditioning unit inwards on the top side. See Fig.
4.

Microsoft
Wednesday, September 16, 2009 5:08:49 PM Page 5 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 5: Releasing and pulling off coolant hoses

Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Press together the spring band clamps for the coolant hoses on the heat exchanger with the mounting pliers
for spring band clamps, Cayenne hose connections 72-1 -arrows A- and pull off the coolant hoses from the
heat exchanger -arrows B- . See Fig. 5.

Microsoft
Wednesday, September 16, 2009 5:08:49 PM Page 6 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 6: Loosening the suction line

Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Unscrew the fastening screw for the suction line in the upper bracket (not on the expansion valve at the
bottom) -1- . See Fig. 6.

7. Remove the suction line and close with plugs.

Microsoft
Wednesday, September 16, 2009 5:08:49 PM Page 7 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 7: Unscrewing fastening screw and removing pressure lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

8. Unscrew the fastening screw for the pressure line in the upper bracket (not on the expansion valve at the
bottom) -1- . See Fig. 6.

9. Remove the pressure line and seal with plugs.

Microsoft
Wednesday, September 16, 2009 5:08:49 PM Page 8 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 8: Raising auxiliary air-conditioning unit and pulling off water drain
Courtesy of PORSCHE OF NORTH AMERICA, INC.

10. Raise auxiliary air-conditioning unit and pull off water drain.

Microsoft
Wednesday, September 16, 2009 5:08:49 PM Page 9 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 9: Removing auxiliary air-conditioning unit

Courtesy of PORSCHE OF NORTH AMERICA, INC.

11. First pull auxiliary air-conditioning unit inward -arrow- and pull out with the coolant hoses and the air-
conditioning lines. See Fig. 9.

INSTALLING AUXILIARY AIR-CONDITIONING UNIT

Installing auxiliary air-conditioning unit

Microsoft
Wednesday, September 16, 2009 5:08:49 PM Page 10 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 10: Running in auxiliary air-conditioning unit

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Position the auxiliary air-conditioning unit.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 11 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 11: Connecting and fastening coolant hoses

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Push the coolant hoses onto the heat exchanger -arrows A- and attach with the spring-band clamps -B- . See
Fig. 11.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 12 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 12: Installing and screwing down the suction line and pressure line
Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Remove the plugs on the suction line and pressure line, check the O-rings of the refrigerant lines, and replace
if in doubt.

4. Place the suction line and pressure line on the connection -arrow- and screw down the fastening screw -1- . --
> Tightening torque: 12 (9.0 ftlb.) Nm See Fig. 12.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 13 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 13: Holding auxiliary air-conditioning unit and connecting water drain
Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Hold auxiliary air-conditioning unit and connect water drain. Ensure that the water drain remains connected
to the drain when fitting the auxiliary air-conditioning unit.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 14 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 14: Tightening fastening screws

Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Press the auxiliary air-conditioning unit on the side wall and screw down the three fastening screws -4- . -->
Tightening torque: 8 (6.0 ftlb.) Nm See Fig. 14.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 15 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 15: Connecting plug connections

Courtesy of PORSCHE OF NORTH AMERICA, INC.

7. Push on the electrical plug -A- and -B- until plug is felt to engage. See Fig. 15.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 16 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 16: Sliding air duct into the air-conditioning unit

Courtesy of PORSCHE OF NORTH AMERICA, INC.

8. Push the air duct into the auxiliary air-conditioning unit until the air duct engages.

SUBSEQUENT WORK

Subsequent work

1. Fill in refrigerant. Refer to 87 03 17 Adding refrigerant and removing by suction - as of MY 2003 (All
Models) .

2. Top up engine coolant. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY
2003 (All Models) .

3. Install rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

4. Install left rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liners -
as of MY 2003 (All Models) .

5. Install rear left wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .

88 20 19 REMOVING AND INSTALLING SERVO MOTORS - AS OF MY 2003

(ALL MODELS)
Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 17 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

PRELIMINARY WORK

Preliniary work - removing servo motor on additional air conditioner

Remove rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

Preliminary work - removing servo motor on central vent

Remove center console. Refer to 68 17 19 Removing and installing center console - as of MY 2003 (All
Models) .

Preliminary work - removing servo motor for footwell/B-pillar vents

1. Remove front seat. Refer to 72 01 19 REMOVING AND INSTALLING FRONT SEAT - AS OF MY

2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN) .

2. Remove center console. Refer to 68 17 19 Removing and installing center console - as of MY 2003 (All
Models) .

REMOVING SERVO MOTOR

Removing servo motor on additional air conditioner

Installation Location:

Fig. 17: Overview of servo motor on additional air conditioner

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Servo motor for air flow, left side

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 18 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

2 - Servo motor for air flow, right side

Fig. 18: Removing air duct from air conditioner

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Compress air duct from above and pull it out of the air conditioner -arrow- . See Fig. 18.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 19 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 19: Loosen fastening screws and tilt inward

Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE:  Only when removing the left servo motor

2. Unscrew the fastening screws -1- and tilt the additional air conditioner inwards at the top side. See Fig. 19.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 20 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 20: Pulling off connector

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Release connector -Arrow A- and pull off -Arrow B- . See Fig. 20.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 21 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 21: Loosen servo motor and remove from the air flow flap.
Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Unscrew the fastening screws -2- and pull the servo motor from the air flow flap -arrow- . See Fig. 21.

Removing servo motor on central vents

Installation Location:

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 22 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 22: Overview of servo motor central vents

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 23: Pulling off connector and loosening servo motor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Release connector -Arrow A- and pull off -Arrow B- . See Fig. 23.

2. Undo the fastening screws -Arrows 2- and remove the servo motor -Arrow C- . See Fig. 23.

Removing servo motor for footwell/B-pillar vents

Installation Location:

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 23 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 24: Overview of servo motor for footwell/B-pillar vents

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 25: Fold up floor carpeting, unplug connector and remove servo motor
Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Fold up the floor carpeting -Arrow A- . See Fig. 25.

2. Release connector -Arrow B- and pull off -Arrow C- . See Fig. 25.
Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 24 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

3. Undo the fastening screws -Arrows 2- and remove the servo motor -Arrow D- . See Fig. 25.

INSTALLING SERVO MOTOR

Installing servo motor on additional air conditioner

Fig. 26: Pushing on servo motor and screwing it down

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Push the servo motor onto the shaft of the air flow flap -arrow- . See Fig. 26.

2. Twist servo motor with air flap into the fastening position -Arrows B- and screw down with the fastening
screws -Arrows 2- . --> Tightening torque: 1.0 ftlb. See Fig. 26.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 25 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 27: Inserting the connectors

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Push on connector -Arrow A- until the locking tab -B- is felt to engage. See Fig. 27.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 26 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 28: Tilt additional air conditioner inward and screw down
Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: Only when installing the left servo motor

4. Tilt the additional air conditioner inwards at the top side -arrow- and screw down with the fastening screws -
Arrows 1- . --> Tightening torque: 6 ftlb. See Fig. 28.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 27 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 29: Push air duct into additional air conditioner

Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Push the air duct into the additional air conditioner -arrow- until the air duct is felt to engage. See Fig. 29.

Installing servo motor on central vents

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 28 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 30: Pushing servo motor onto air flap and fastening
Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Push servo motor onto the air flap -Arrow A- and turn to the fastening position. See Fig. 30.

2. Screw down the servo motor with the fastening screws -Arrows 2- . --> Tightening torque: 1.0 ftlb. See
Fig. 30.

3. Push on connector -Arrow B- until the locking tab -C- is felt to engage. See Fig. 30.

Installing servo motor for footwell/B-pillar vents

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 29 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 31: Pushing on, positioning and screwing servo motor down
Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Push servo motor onto the air flap -A- and turn to the fastening position. See Fig. 31.

2. Screw down the servo motor with the fastening screws -Arrow 2- . --> Tightening torque: 1.0 ftlb. See Fig.
31.

3. Push on connector -Arrow B- until the locking tab -Arrow C- is felt to engage. See Fig. 31.

4. Fold back floor carpeting -Arrow D- . See Fig. 31.

SUBSEQUENT WORK

Subsequent work - Installing servo motor on additional air conditioner

Install rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-trim
panel - as of MY 2003 (All Models) .

Subsequent work - Installing servo motor on central vent

Install center console. Refer to 68 17 19 Removing and installing center console - as of MY 2003 (All
Models) .

Subsequent work - installing servo motor for footwell/B-pillar vents

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 30 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

1. Install center console. Refer to 68 17 19 Removing and installing center console - as of MY 2003 (All
Models) .

2. Install front seat. Refer to 72 01 19 Removing and installing front seat - as of MY 2003 (All Models
Except Cayenne S TIO Titan) .

88 23 19 REMOVING AND INSTALLING HEAT EXCHANGER - AS OF MY

2003 (ALL MODELS)
TOOLS

Designation Type Number Explanation

circlip pliers for spring commercially 72-1
band clamps, Cayenne hose available tool
connections

PRELIMINARY WORK

Preliminary work

1. Drain engine coolant. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY
2003 (All Models) .

2. Remove rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

REMOVING HEAT EXCHANGER

Installation Location:

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 31 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 32: Overview of heat exchanger

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 33: Pulling out the air duct from the air-conditioning unit
Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Press together the air duct from above and pull out of the air-conditioning unit -arrow- . See Fig. 33.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 32 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 34: Tilting the auxiliary air-conditioning unit inwards

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Unscrew the fastening screws -1- and tilt the auxiliary air-conditioning unit inwards on the top side. See Fig.
34.

3. Remove both servo motors for air flow. --> 882019 Removing and installing servo motor - chapter on
"Removing"

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 33 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 35: Releasing and pulling off coolant hoses

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Press together the spring band clamps with the circlip pliers for spring band clamps, Cayenne hose
connections 72-1 -arrows A- and pull off the coolant hoses from the heat exchanger -arrows B- . See Fig. 35.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 34 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 36: Opening the upper housing section and removing the heat exchanger
Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Unscrew fastening screws -2- and open the upper housing section -arrow A- . See Fig. 36.

6. Take out heat exchanger -arrow B- . See Fig. 36.

INSTALLING HEAT EXCHANGER

NOTE:  Both foam seals position the evaporator under a slight pre-load in the
housing. To ensure the correct pre-load, any damaged foam seal must be
replaced.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 35 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 37: Installing heat exchanger and closing upper housing section
Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Insert heat exchanger into housing -arrow A- . See Fig. 37.

2. Fold up upper housing section -arrow B- and screw down with the fastening screws -2- . --> Tightening
torque: 1 ftlb. See Fig. 37.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 36 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 38: Connecting and fastening coolant hoses

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Push the coolant hoses onto the heat exchanger -arrows A- and attach with the spring-band clamps -B- . See
Fig. 38.

4. Install both servo motors for air flow. --> 882019 Removing and installing servo motor - chapter on
"Installing"

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 37 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 39: Tilting the and screwing down auxiliary air-conditioning unit inwards
Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Tilt in the auxiliary air-conditioning unit on the top side -arrows- and screw down with the fastening screws -
1- . --> Tightening torque: 6 ftlb. See Fig. 39.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 38 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 40: Sliding air duct into the auxiliary air-conditioning unit
Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Push the air duct into the auxiliary air-conditioning unit -arrow- until the air duct is felt to engage. See Fig.
40.

SUBSEQUENT WORK

Subsequent work

1. Install rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

2. Top up engine coolant. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY
2003 (All Models) .

88 34 19 REMOVING AND INSTALLING AUXILIARY AIR-CONDITIONING AIR

GUIDE - AS OF MY 2003 (ALL MODELS)
REMOVING AUXILIARY AIR-CONDITIONING AIR GUIDE

NOTE:  Depending on vehicle equipment and on the required air guide, all interior
components must be removed.
 The removal and installation described provides information about routing

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 39 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

and the connection or fastening points.

Installation Location:

Fig. 41: Overview of air guide for auxiliary air-conditioning

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 42: Pulling out the air duct from the air-conditioning unit
Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 40 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Press together the air duct from above and pull out of the air-conditioning unit.

Fig. 43: Removing vent

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Unscrew fastening screws -1- and remove the vents -arrow- . See Fig. 43.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 41 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 44: Unscrewing fastening elements

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Unscrew the fastening screws -1- and the fastening nuts -2- . See Fig. 44.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 42 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 45: Disconnecting air guides

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. The air guides are plugged into each other and can simply be pulled apart.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 43 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 46: Disconnecting rear footwell vent air guides and B-pillar
Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Unscrew the fastening screws -1- and pull apart the rear footwell vent air guides and the B-pillar. See Fig. 46.

INSTALLING AUXILIARY AIR-CONDITIONING AIR GUIDE

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 44 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 47: Plugging together the rear footwell vent air guides and B-pillar
Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Plug together the rear footwell vent air guides and the B-pillar and screw down with the fastening screws -1- .
--> Tightening torque: 1 ftlb. See Fig. 47.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 45 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 48: Plugging the air guides together

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Plug the air guides together.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 46 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 49: Screwing down air guides

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Screw down the air guides using the fastening screws -1- and the fastening nuts -2- . --> Tightening torque:
1 ftlb. --> Tightening torque: 1 ftlb. See Fig. 49.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 47 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 50: Sliding air duct into the auxiliary air-conditioning unit
Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Push the air duct into the auxiliary air-conditioning unit until the air duct engages.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 48 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 51: Positioning and screwing down the center console

Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Place on the center console vent and screw down with the fastening screws -1- . --> Tightening torque: 1
ftlb. See Fig. 51.

88 48 19 REMOVING AND INSTALLING CONTROL UNIT FOR AUXILIARY

AIR CONDITIONER - AS OF MY 2003 (ALL MODELS)
REMOVING CONTROL UNIT FOR AUXILIARY AIR CONDITIONER

NOTE:  The control unit for the auxiliary air conditioning system is located in the
center console, back seat area.

NOTE:  The ignition must be switched off and the ignition key removed before the
control unit for the auxiliary air conditioning system can be removed.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 49 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 52: Removing control module

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Use a plastic spatula to carefully unclip the covering frame, left and right.

2. Unscrew both fastening screws -1- . See Fig. 52.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 50 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 53: Pulling off plug

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Press in latch of electrical plugs -a- and pull the plugs up and off. See Fig. 53.

INSTALLING CONTROL UNIT FOR AUXILIARY AIR CONDITIONER

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 51 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 54: Inserting the connectors

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Press electrical plugs into control module until they are felt to engage.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 52 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 55: Installing control module

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Carefully slide the control unit into the installation slot, paying attention to the electrical leads.

3. Screw in the two fastening screws -1- . See Fig. 55.

4. Fit the covering frame and press into place until it is felt to engage.

88 54 19 REMOVING AND INSTALLING TEMPERATURE SENSOR - AS OF

MY 2003 (ALL MODELS)
PRELIMINARY WORK

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 53 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Preliminary work

1. Remove rear roof trim panel. Refer to 70 85 19 Removing and installing rear roof lining - as of MY 2003
(All Models) .

2. Remove D-pillar trim panel. Refer to 70 69 19 Removing and installing D-pillar trim - as of MY 2003 (All
Models) .

3. Remove C-pillar trim panel. Refer to 70 68 19 Removing and installing C-pillar trim panel - as of MY
2003 (All Models) .

4. Remove trim panel for left luggage compartment floor with tie-down ring. Refer to 70 06 19 Removing and
installing luggage compartment trim (loadspace cover) - as of MY 2003 (All Models) .

5. Remove left rear backrest. Refer to 72 47 19 Removing and installing rear backrest - as of MY 2003 (All
Models) .

6. Remove rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

REMOVING TEMPERATURE SENSOR

Removing temperature sensor for left side

Installation Location:

Fig. 56: Overview of temperature sensor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Temperature sensor, right side

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 54 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

2 - Temperature sensor, left side

Fig. 57: Folding carpeted floor forwards

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Fold carpeted floor forwards.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 55 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 58: Removing left temperature sensor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Turn the temperature sensor to the outside of the vehicle -arrow A- and remove it -arrow B- . See Fig. 58.

3. Release the plug -arrows C- and pull off -arrow D- . See Fig. 58.

Removing temperature sensor for right side

Installation Location:

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 56 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 59: Overview of temperature sensor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Temperature sensor, right side

2 - Temperature sensor, left side

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 57 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 60: Removing right temperature sensor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Turn the temperature sensor to the inside of the vehicle -arrow A- and remove it from the air duct -arrow B-
. See Fig. 60.

2. Release the plug -arrows C- and pull off -arrow D- . See Fig. 60.

INSTALLING TEMPERATURE SENSOR

Installing temperature sensor for left side

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 58 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 61: Installing left temperature sensor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Check sealing ring for signs of damage -a- and replace if necessary. See Fig. 61.

2. Insert the plug -arrow A- until the locking tabs -arrows B- are felt to engage. See Fig. 61.

3. Insert temperature sensor -arrow C- and turn it to the inside of the vehicle -arrow D- until the locking tabs -
b- engage. See Fig. 61.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 59 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 62: Folding back the carpeted floor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Fold back the carpeted floor -arrow- and align it. See Fig. 62.

Installing temperature sensor for right side

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 60 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 63: Installing right temperature sensor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Check sealing ring -a- for signs of damage and replace if necessary. See Fig. 63.

2. Insert the plug -arrow A- until the locking tabs -arrows B- are felt to engage. See Fig. 63.

3. Insert temperature sensor -arrow C- and turn it to the inside of the vehicle -arrow D- until the locking tabs -
b- engage. See Fig. 63.

SUBSEQUENT WORK

Subsequent work

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 61 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

1. Install rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

2. Install left rear backrest. Refer to 72 47 19 Removing and installing rear backrest - as of MY 2003 (All
Models) .

3. Install trim panel for left luggage compartment floor with tie-down ring. Refer to 70 06 19 Removing and
installing luggage compartment trim (loadspace cover) - as of MY 2003 (All Models) .

4. Install C-pillar trim panel Refer to 70 68 19 Removing and installing C-pillar trim panel - as of MY 2003
(All Models) .

5. Install D-pillar trim panel. Refer to 70 69 19 Removing and installing D-pillar trim - as of MY 2003 (All
Models) .

6. Install rear roof trim panel. Refer to 70 85 19 Removing and installing rear roof lining - as of MY 2003
(All Models) .

88 60 19 REMOVING AND INSTALLING EVAPORATOR - AS OF MY 2003

(ALL MODELS)
PRELIMINARY WORK

Preliminary work

1. Remove rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

2. Remove additional air conditioner. --> 881019 Removing and installing additional air conditioner -
chapter on "removing"

3. Remove expansion valve. --> 887019 Removing and installing expansion valve for additional air
conditioner - chapter on "removing"

REMOVING EVAPORATOR

Installation Location:

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 62 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 64: Overview of evaporator

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 65: Unscrewing fastening screws

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Unscrew fastening screws -arrows 1- . See Fig. 65.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 63 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 66: Removing lower housing section with the evaporator

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Release both locking hooks -arrows A- and take out the bottom housing section with the evaporator -arrow
B- . See Fig. 66.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 64 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 67: Releasing and taking out the cover

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Unscrew the fastening screws -arrows 2- and unscrew the cover -arrow B- . See Fig. 67.

4. Take the evaporator out of the lower housing section arrow -arrow B- . See Fig. 67.

INSTALLING EVAPORATOR

NOTE:  The seal positions the evaporator under a slight pre-load in the housing.
To ensure the correct pre-load, a damaged seal must be replaced.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 65 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 68: Insert evaporator into lower housing section and fasten.
Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Insert evaporator into lower housing section -arrow A- . See Fig. 68.

2. Insert the cover -arrow B- and screw in the fastening screws -2- - do not screw them down! See Fig. 68.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 66 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 69: Slipping the lower housing section onto the upper housing section
Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Slip the lower housing section onto the upper housing section -arrow A- until locking tabs -arrows B- are
felt to engage. See Fig. 69.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 67 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 70: Tightening fastening screws

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Screw on fastening screws -arrows 1- and tighten. --> Tightening torque: 1 ftlb. See Fig. 70.

5. Screw down the cover with the fastening screws -2- . --> Tightening torque: 1 ftlb. See Fig. 70.

SUBSEQUENT WORK

Subsequent work

1. Install expansion valve. --> 887019 Removing and installing expansion valve for additional air
conditioner - chapter on "installing"

2. Install additional air conditioner. --> 881019 Removing and installing additional air conditioner - chapter
on "installing"

3. Install rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

88 68 19 REMOVING AND INSTALLING BLOWER MOTOR - AS OF MY 2003

(ALL MODELS)
PRELIMINARY WORK

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 68 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Preliminary work

Remove additional air conditioner. --> 881019 Removing and installing additional air conditioner - chapter
on "removing"

REMOVING BLOWER MOTOR

Installation Location:

Fig. 71: Overview of blower motor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 69 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 72: Pulling off plug

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Release the plug -arrows A- and pull off -arrow B- . See Fig. 72.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 70 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 73: Releasing blower motor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Release the locking tab -arrow A- and twist the blower motor up to the stop -a- -arrow B- . See Fig. 73.

3. Take out blower motor -arrow C- . See Fig. 73.

INSTALLING BLOWER MOTOR

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 71 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 74: Installing blower motor

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Insert the blower motor -arrow A- and twist to the left -arrow B- , until the locking hook can be felt to
engage in the twist lock -b- -arrow C- . See Fig. 74.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 72 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 75: Inserting the connectors

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Insert the plug -arrow A- until the locking tabs -arrows B- are felt to engage. See Fig. 75.

SUBSEQUENT WORK

Subsequent work

Install additional air conditioner. --> 881019 Removing and installing additional air conditioner - chapter
on "installing"

88 70 19 REMOVING AND INSTALLING EXPANSION VALVE FOR

AUXILIARY AIR CONDITIONER - AS OF MY 2003 (ALL MODELS)
PRELIMINARY WORK

Preliminary work

Remove rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

REMOVING EXPANSION VALVE

CAUTION: Danger of injury from contact with the refrigerant

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 73 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

--> Observe safety regulations when working with refrigerant. --> 80 AW SAFETY REGULATIONS FOR
EXTRACTION AND FILLING SYSTEMS - AS OF MY 2003 (ALL MODELS) .

Installation Location:

Fig. 76: Overview of expansion valve

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Remove refrigerant by suction. Refer to 87 03 17 Adding refrigerant and removing by suction - as of MY

2003 (All Models) .

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 74 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 77: Undo fastening screws for refrigerant lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Undo the two fastening screws -1- for the expansion valve refrigerant lines. See Fig. 77.

3. Pull out refrigerant lines from expansion valve and close with plugs.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 75 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 78: Loosening and removing expansion valve

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Undo the two fastening screws for the expansion valve -2- and remove expansion valve. See Fig. 78.

INSTALLING EXPANSION VALVE

NOTE:  Before the expansion valve is re-installed, the O-rings of the refrigerant
lines must be checked for damage and replaced if necessary.
 Wet the O-rings of the refrigerant lines with refrigerant oil.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 76 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 79: Installing and screwing down expansion valve

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Carefully push expansion valve onto refrigerant lines from evaporator - do not tilt.

2. Insert the two fastening screws -2- and tighten. --> Tightening torque: 6.5 ftlb. See Fig. 79.

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 77 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 80: Tightening fastening screws of refrigerant lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Carefully push refrigerant lines onto expansion valve (do not tilt) and tighten with the two fastening screws -
1- . --> Tightening torque: 7.5 ftlb. See Fig. 80.

SUBSEQUENT WORK

Subsequent work

1. Install rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

2. Fill in refrigerant. Refer to 87 03 17 Adding refrigerant and removing by suction - as of MY 2003 (All
Models) .

88 75 19 REMOVING AND INSTALLING VENTS - AS OF MY 2003 (ALL

MODELS)
TOOLS

Designation Type Number Explanation

disassembly tool, universal special tool NR.21

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 78 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

REMOVING VENT

Removing B-pillar vent

Remove vent. Refer to 70 67 19 Removing and installing B-pillar trim panel - as of MY 2003 (All Models) .

Removing center console vent

Fig. 81: Use of disassembly tool, universal No. 21

Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE:  Slide in the disassembly tool, universal NR.21 so that, when levering out, it
rests on the vent -2- and not on the cover -1- .

Installation Location:

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 79 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 82: Overview of center console vent

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Lever out the vent all the way around with the disassembly tool, universal NR.21 and remove it.

INSTALLING VENT

Installing B-pillar vent

Install vent. Refer to 70 67 19 Removing and installing B-pillar trim panel - as of MY 2003 (All Models) .

Installing center console vent

Microsoft
Wednesday, September 16, 2009 5:08:50 PM Page 80 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 83: Positioning center console vent

Courtesy of PORSCHE OF NORTH AMERICA, INC.

center the vent with the ring markings -3- pointing upwards and press it in -Arrow- until the locking tabs can be
felt to engage. See Fig. 83.

88 76 19 REMOVING AND INSTALLING SUCTION LINE IN VEHICLE - AS OF

MY 2003 (ALL MODELS)
PRELIMINARY WORK

Preliminary work

1. Remove rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

2. Unscrew auxiliary air-conditioning unit. --> 881019 Removing and installing auxiliary air-conditioning
unit

REMOVING SUCTION LINE IN VEHICLE

CAUTION: Danger of injury from contact with the refrigerant

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 81 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

--> Observe safety regulations when working with refrigerant. --> 80 AW SAFETY REGULATIONS FOR
EXTRACTION AND FILLING SYSTEMS - AS OF MY 2003 (ALL MODELS) .

Installation Location:

Fig. 84: Overview of suction line in vehicle

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Remove refrigerant by suction. Refer to 87 03 17 Adding refrigerant and removing by suction - as of MY

2003 (All Models) .

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 82 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 85: Loosing suction lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Raise the auxiliary air-conditioning unit and unscrew both fastening screws -1- . See Fig. 85.

3. Remove the suction line -Arrows- and close with plugs. See Fig. 85.

INSTALLING SUCTION LINE IN VEHICLE

1. Remove the plugs on the suction line, check the O-rings and replace if in doubt.

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 83 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 86: Positioning and screwing down suction lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Raise the auxiliary air-conditioning unit and push the suction line onto the connections -arrows- and screw
down with both fastening screws -1- . --> Tightening torque: 12 (9.0 ftlb.) Nm See Fig. 86.

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 84 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 87: Holding auxiliary air-conditioning unit and connecting water drain
Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Ensure that the water drain is connected to the drain when fitting the auxiliary air-conditioning unit.

SUBSEQUENT WORK

Subsequent work

1. Fill in refrigerant. Refer to 87 03 17 Adding refrigerant and removing by suction - as of MY 2003 (All
Models) .

2. Screw down auxiliary air-conditioning unit. --> 881019 Removing and installing auxiliary air-
conditioning unit

3. Install rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

88 77 19 REMOVING AND INSTALLING VEHICLE FLOOR INTAKE PIPE

(LOW PRESSURE) - AS OF MY 2003 (ALL MODELS)
PRELIMINARY WORK

Preliminary work - removing front vehicle floor suction line

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 85 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

1. Remove left front wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .

2. Remove left front wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing
liner - as of MY 2003 (All Models) .

3. Remove left center cover. Refer to 51 93 19 Removing and installing middle cover - as of MY 2003 (All
Models) .

Preliminary work - removing rear vehicle floor suction line

1. Remove left rear wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .

2. Remove left rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liners
- as of MY 2003 (All Models) .

3. Remove left center cover. Refer to 51 93 19 Removing and installing middle cover - as of MY 2003 (All
Models) .

REMOVING THE VEHICLE FLOOR INTAKE PIPE

Removing front vehicle floor suction line

CAUTION: Danger of injury from contact with the refrigerant

--> Observe safety regulations when working with refrigerant. --> 80 AW SAFETY REGULATIONS FOR
EXTRACTION AND FILLING SYSTEMS - AS OF MY 2003 (ALL MODELS) .

NOTE:  Remove and install the pressure line together with the suction line.

1. Remove refrigerant by suction. Refer to 87 03 17 Adding refrigerant and removing by suction - as of MY

2003 (All Models) .

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 86 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 88: Loosening and plugging refrigerant lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Unscrew the fastening screws -2- for the refrigerant lines, then seal the refrigerant lines -A- (low pressure)
and -B- (high pressure) and the connections with plugs. See Fig. 88.

Fig. 89: Removing refrigerant lines part 1

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Unscrew the fastening screws -4- for the refrigerant lines -A- and -B- . See Fig. 89.

4. Unscrew the fastening screws -5- of the support for the refrigerant lines -A- , -B- and coolant lines -C- . See
Fig. 89.
Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 87 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

5. Unclip lines -A, B, C- from the support. See Fig. 89.

Fig. 90: Removing refrigerant lines part 2

Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Unscrew the fastening screws -4- for the refrigerant lines -A- , -B- and for the coolant line -C- . See Fig. 90.

7. Unscrew the fastening screws -2- for the refrigerant lines, then seal the refrigerant lines, -A- (low pressure)
and -B- (high pressure), and the connections with plugs. See Fig. 90.

8. Pull out refrigerant lines -A- (low pressure) and -B- (high pressure) together. Unclip lines from the retaining
clips. See Fig. 90.

Removing the rear vehicle floor suction line

CAUTION: Danger of injury from contact with the refrigerant

--> Observe safety regulations when working with refrigerant. --> 80 AW SAFETY REGULATIONS FOR
EXTRACTION AND FILLING SYSTEMS - AS OF MY 2003 (ALL MODELS) .

1. Remove refrigerant by suction. Refer to 87 03 17 Adding refrigerant and removing by suction - as of MY

2003 (All Models) .

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 88 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 91: Loosening and plugging refrigerant lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Unscrew the fastening screws -2- for the refrigerant lines, then unclip the refrigerant lines -A- (low pressure)
and -B- (high pressure) from the support -D- . Seal the connections and refrigerant lines with plugs. See Fig. 91.

Fig. 92: Unscrewing fastening screws

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Unscrew the fastening screws -4- for the refrigerant lines -B- and for the coolant line Kuhlmittelleitung -C- .
See Fig. 92.

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 89 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 93: Removing refrigerant lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Unscrew the fastening screws -4- for the refrigerant lines -A- , -B- and for the coolant line -C- . See Fig. 93.

5. Unscrew the fastening screws -2- for the refrigerant lines, then seal the refrigerant lines, -A- (low pressure)
and -B- (high pressure), and the connections with plugs. See Fig. 93.

6. Pull out refrigerant lines -A- (low pressure) and -B- (high pressure) together. Unclip lines from the retaining
clips. See Fig. 93.

INSTALLING THE VEHICLE FLOOR INTAKE PIPE

Installing the front vehicle floor suction line

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 90 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 94: Installing refrigerant lines part 2

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Remove the plugs for the refrigerant lines -A- and -B- , check the O-rings of the refrigerant lines and replace
if in doubt. See Fig. 94.

2. Clip in the refrigerant lines into the retaining clips and coat the O-rings with refrigerant oil. Slide in lines and
tighten using both fastening screws -2- . --> Tightening torque: 9 ftlb. See Fig. 94.

3. Push fastening screws -4- through the retaining clips for the lines -A, B, C- and tighten. --> Tightening
torque: 2.5 ftlb. See Fig. 94.

Fig. 95: Installing refrigerant lines part 1

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 91 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Clip lines -A, B, C- into the support. See Fig. 95.

5. Position support with lines on the body and screw down with fastening screws -5- . --> Tightening torque:
4.5 ftlb. See Fig. 95.

6. Position refrigerant lines -A, B- in the wheel housing and screw down with fastening screws -4- . -->
Tightening torque: 2.5 ftlb. See Fig. 95.

Fig. 96: Remove plugs and fasten refrigerant lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

7. Remove the plugs for the refrigerant lines -A- and -B- , check the O-rings of the refrigerant lines and replace
if in doubt. See Fig. 96.

8. Coat the O-rings with refrigerant oil. Slide in lines and tighten using both fastening screws -2- . -->
Tightening torque: 9 ftlb. See Fig. 96.

Installing the rear vehicle floor suction line

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 92 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 97: Installing refrigerant lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Remove the plugs for the refrigerant lines -A- and -B- , check the O-rings of the refrigerant lines and replace
if in doubt. See Fig. 97.

2. Clip in the refrigerant lines into the retaining clips and coat the O-rings with refrigerant oil. Slide in lines and
tighten using both fastening screws -2- . --> Tightening torque: 9 ftlb. See Fig. 97.

3. Push fastening screws -4- through the retaining clips for the lines -A, B, C- and tighten. --> Tightening
torque: 2.5 ftlb. See Fig. 97.

Fig. 98: Tightening fastening screws

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 93 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Position refrigerant lines -A, B- and coolant lines -C- and tighten with fastening screws -4- . --> Tightening
torque: 2.5 ftlb. See Fig. 98.

Fig. 99: Installing and fastening refrigerant lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Remove the plugs for the refrigerant lines -A- and -B- , check the O-rings of the refrigerant lines and replace
if in doubt. See Fig. 99.

6. Clip refrigerant lines into the retaining clips -D- and coat the O-rings with refrigerant oil. Slide in lines -A, B-
and tighten using both fastening screws -2- . --> Tightening torque: 9 ftlb. See Fig. 99.

SUBSEQUENT WORK

Subsequent work - installing front vehicle floor suction line

1. Fill in refrigerant. Refer to 87 03 17 Adding refrigerant and removing by suction - as of MY 2003 (All
Models) .

2. Install left front wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .

3. Install left front wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner
- as of MY 2003 (All Models) .

4. Install left center cover. Refer to 51 93 19 Removing and installing middle cover - as of MY 2003 (All
Models) .

Subsequent work - installing rear vehicle floor suction line

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 94 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

1. Fill in refrigerant. Refer to 87 03 17 Adding refrigerant and removing by suction - as of MY 2003 (All
Models) .

2. Install left rear wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .

3. Install left rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liners -
as of MY 2003 (All Models) .

4. Install left center cover. Refer to 51 93 19 Removing and installing middle cover - as of MY 2003 (All
Models) .

88 78 19 REMOVING AND INSTALLING BLOWER REGULATOR - AS OF MY

2003 (ALL MODELS)
PRELIMINARY WORK

Preliminary work

Remove rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

REMOVING BLOWER REGULATOR

CAUTION: Danger of damage and injury!

--> Remove ignition key.

--> First pull out the plug contacts on the switch before the fan control is removed.

Installation Location:

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 95 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 100: Overview of fan control

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 101: Pulling off plug

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Release both electrical connectors -Arrows A- and unplug them -Arrows B- . See Fig. 101.

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 96 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 102: Releasing and removing the fan control

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Unscrew the two fastening screws -1- and remove the fan control -Arrow- . See Fig. 102.

INSTALLING BLOWER REGULATOR

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 97 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 103: Installing and screwing down fan control

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Insert the fan control einstecken -Arrow- and screw down with the fastening screws -1- . --> Tightening
torque: 1.0 ftlb. See Fig. 103.

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 98 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 104: Inserting the connectors

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Push in both connectors -Arrows A- until the locking tabs -Arrows B- are felt to engage. See Fig. 104.

SUBSEQUENT WORK

Subsequent work

Install rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-trim
panel - as of MY 2003 (All Models) .

88 83 19 REMOVING AND INSTALLING PRESSURE LINE IN VEHICLE - AS

OF MY 2003 (ALL MODELS)
PRELIMINARY WORK

Preliminary work

1. Remove rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

2. Unscrew auxiliary air-conditioning unit. --> 881019 Removing and installing auxiliary air-conditioning
unit

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 99 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

REMOVING PRESSURE LINE IN VEHICLE

CAUTION: Danger of injury from contact with the refrigerant

--> Observe safety regulations when working with refrigerant. --> 80 AW SAFETY REGULATIONS FOR
EXTRACTION AND FILLING SYSTEMS - AS OF MY 2003 (ALL MODELS) .

Installation Location:

Fig. 105: Overview of pressure line in vehicle

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Remove refrigerant by suction. Refer to 87 03 17 Adding refrigerant and removing by suction - as of MY

2003 (All Models) .

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 100 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 106: Unscrewing fastening screws and removing pressure lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Raise the auxiliary air-conditioning unit and unscrew both fastening screws -1- . See Fig. 106.

3. Remove the pressure line -Arrows- and seal with plugs. See Fig. 106.

INSTALLING PRESSURE LINE IN VEHICLE

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 101 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 107: Installing and screwing down pressure lines

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Remove the plugs on the pressure line, check the O-rings and replace if in doubt.

2. Raise the auxiliary air-conditioning unit and push the pressure line onto the connections -arrow- and screw
down with both fastening screws -1- . --> Tightening torque: 12 (9.0 ftlb.) Nm See Fig. 107.

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 102 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

Fig. 108: Holding auxiliary air-conditioning unit and connecting water drain
Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Ensure that the water drain is connected to the drain when fitting the auxiliary air-conditioning unit.

SUBSEQUENT WORK

Subsequent work

1. Fill in refrigerant. Refer to 87 03 17 Adding refrigerant and removing by suction - as of MY 2003 (All
Models) .

2. Screw down auxiliary air-conditioning unit. --> 881019 Removing and installing auxiliary air-
conditioning unit

3. Install rear side trim panel. Refer to 70 03 19 Removing and installing rear luggage compartment side-
trim panel - as of MY 2003 (All Models) .

88 84 19 VEHICLE FLOOR PRESSURE LINE (HIGH PRESSURE) - AS OF MY

2003 (ALL MODELS)
INFORMATION

NOTE:  Remove and install the pressure line together with the suction line.

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 103 © 2005 Mitchell Repair Information Company, LLC.
 2006 Porsche Cayenne
2003-2008 HVAC Auxiliary Air Conditioning

 --> 887719 Removing and installing vehicle floor suction line (low
pressure)

Microsoft
Wednesday, September 16, 2009 5:08:51 PM Page 104 © 2005 Mitchell Repair Information Company, LLC.