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    This tutorial is provided as a courtesy by ECS Tuning.

    Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

    Although this material has been prepared with the intent to provide reliable information, no warranty (express or implied) is made as to its accuracy or completeness. Neither is any liability assumed for loss or damage resulting from reliance on this mate-rial. SPECIFICALLY, NO WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER WARRANTY IS MADE OR TO BE IMPLIED WITH RESPECT TO THIS MATERIAL. In no event will ECS Tuning, Incorporated or its affiliates be liable for any damages, direct or indirect, consequential or compensatory, arising out of the use of this material.

    Porsche Cayenne Coolant Pipe Upgrade

    Porsche Cayennewith 4.5L

    (2003-2006)ES2501060 ES2594479 ES2771217 ES2771560

    http://www.ecstuning.com/Search/SiteSearch/ES2501060/ES2501060/http://www.ecstuning.com/Search/SiteSearch/ES2594479/ES2594479/http://www.ecstuning.com/Search/SiteSearch/ES2771217/ES2771217/http://www.ecstuning.com/Search/SiteSearch/ES2771560/ES2771560/

  • Address: 1000 Seville Road, Wadsworth, OH 44281 Phone: 1.800.924.5172 Web: www.ecstuning.com

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    Cayenne Coolant Pipe Upgrade

    Tools We Used fuel line pliers (ES1306816) coolant drain pan T40 Torx driver E10 Torx socket ratchets/extensions/swivel torque wrench clean towels cooling system pressure tester

    Kit Part Number: ES2501060 (other kits similar)

    Single pipe 94810604907 Triple pipe 94810605906 Breather pipe 94810601603 Intake distributor gasket 94811014501 (qty 2) Adapter neck - 94810623000 Coolant hose - 94810624000

    refractometer manual fluid extractor Schwaben coolant evacuation tool kit spring clamp tool 12mm triple square driver 16mm socket

    Fastener bracket (Upper) - 94810625900 Fastener bracket (Lower) - 94810626900 Spacer Bushings - 94810627900 (qty 3) 6x16 Torx screws (qty 3) 35-50 Hose clamp - 99951238901 (qty 2) 47 x 4 o-ring - 99970737041 Tube o-ring grease - 00004320468 Liter container Porsche Coolant - 00004320378 (qty 2)

    We are about to teach a problem child a few manners.

    Porsche Cayenne V8 models from 2003-2006 came from the factory with plastic coolant tubes located beneath the intake manifold that are notorious for leaking. The problem is widespread, and well show you the fix.

    In this procedural, we will remove the original plastic coolant tubes and replace them with new, upgraded alumi-num tubes, included in a special repair kit available from ECS Tuning.

    This is an interesting project, and while there are quite a few steps, it is not an especially high-tech repair. More like advanced automotive plumbing than rocket science.

    We suggest disconnecting the battery before beginning this project. The starter motor and its main positive cable sit right next to the coolant hoses we will be removing, and the fuel lines will be open.

    An ounce of prevention...

    http://www.ecstuning.com/Audi-B7_RS4--V8/Search/SiteSearch/ES2712734/ES2712734/http://www.ecstuning.com/Search/ES2702616/ES2702616/

  • Address: 1000 Seville Road, Wadsworth, OH 44281 Phone: 1.800.924.5172 Web: www.ecstuning.com

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    Cayenne Coolant Pipe Upgrade

    fits 2003-2006 Cayenne V8

    front

    rear

    perimeterjack points

    main chassismount

    lift points

    never work beneath

    any vehicle whilealone

    always support the vehicle

    with approved jack stands

    Please refer to item 1 in the repair sequence to set the vehicle suspension to Service Mode before raising the vehicle.

  • Address: 1000 Seville Road, Wadsworth, OH 44281 Phone: 1.800.924.5172 Web: www.ecstuning.com

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    Cayenne Coolant Pipe Upgrade

    fits 2003-2006 Cayenne V8

    Tool TipsBefore we start, we want to mention a few special tools that make this job much easier. You may want to consider adding them to your tool inventory.

    Spring Clamp ToolThe Schwaben Locking Hose Clamp Pliers allow technicians to access the flat-type hose clamps located in hard-to-access areas. The pliers have a locking mechanism to hold clamps in the open position, making the removal and installation of clamps much easier.

    Coolant Evacuation KitThe Schwaben Coolant Evacuation Tool Kit is used universally among all vehicles using the Venturi method to ensure that there will be no air pockets when refilling the cooling system and can help identify if leaks are present. Once you are sure the system is ready you can add your coolant with the opening of the valve, after the pressure gauge reads 0 the system is filled.

    RefractometerA refractometer is the most accurate way to measure the specific gravity of the coolant mix to ensure proper freeze protection. Use the eyedropper tube to place a few drops of coolant on the sample window beneath the clear plastic cover, and peer through the eyepiece to see the exact water-to-coolant ratio and freeze protection, displayed on a numeric scale.

    Look for 34 degrees F, indicating a 50/50 mix. Remember, too much antifreeze is not a good thing. Never exceed a 60:40 ratio of antifreeze:mixing water.

    http://www.ecstuning.com/Search/SiteSearch/ES2702616/ES2702616/http://www.ecstuning.com/Search/SiteSearch/ES2712734/ES2712734/

  • Address: 1000 Seville Road, Wadsworth, OH 44281 Phone: 1.800.924.5172 Web: www.ecstuning.com

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    Cayenne Coolant Pipe Upgrade

    fits 2003-2006 Cayenne V8

    radiator

    rewall

    boost pressure sensor

    torque arm

    fuel lines

    air injectionpump

    air injectionpump

    fuel rail

    intake manifold bolts

    y-shaped inlet tube

    throttle motor

    intake manifold

    injectors =

    component locator

    oil cap

    beauty coverleft

    beauty coverright

    fuel rail service ports

    coolant jug

    Well start you off with this birds eye view of the engine compartment layout. Take a few moments to familiarize yourself with major components and their locations.

    The coolant pipes we are replacing in this tutorial are located beneath the intake manifold. The intake manifold is made of plastic, and held in place by 10 fasteners.

    In addition to the manifold-throttle body assembly, we must also remove the front air intake Y-pipe and disconnect all sensors, fuel injectors, and fuel, vapor and vacuum lines attached to the manifold and throttle body.

    Refer back to this legend as needed to identify components and their locations.

  • Address: 1000 Seville Road, Wadsworth, OH 44281 Phone: 1.800.924.5172 Web: www.ecstuning.com

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    Cayenne Coolant Pipe Upgrade

    fits 2003-2006 Cayenne V8

    starter

    coolant hoses

    rewall

    radiator

    large pipealuminum update

    main coolant hoses

    large coolant pipeinstalled

    thermostst housing

    rear coolant plenum

    starter

    breather hose

    tape over intake ports

    starter

    coolant hoses

    rewall

    radiator

    triple pipealuminum update

    main coolant hoses

    top pipes installedthermostat

    housing

    This view shows the engine after the intake manifold is removed.

    Note the location of the three smaller coolant pipes and their installed location between the thermostat housing and rubber coolant hoses at the rear of the engine.

    Also note the location of the breather hose included in your kit.

    This image shows the engine with the smaller triple pipes removed. The large coolant pipe is located one floor down, beneath the triple coolant pipe array above it.

    The large pipe connects the thermostat housing to the coolant plenum that straddles the rear of the engine.

    Now that you have your bearings, lets get started.

  • Address: 1000 Seville Road, Wadsworth, OH 44281 Phone: 1.800.924.5172 Web: www.ecstuning.com

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    Cayenne Coolant Pipe Upgrade

    fits 2003-2006 Cayenne V8

    2) Disconnect the battery (located beneath the driver seat). The easiest way to do this is to pop off the carpeted cover from the front of the driver seat base to expose the front of the battery.

    Then unbolt the main ground strap between the battery and body.

    1) (Vehicles with air suspension only) If raising the vehicle off its wheels, Porsche recommends setting the suspension to service mode. Ignition on, push the rocker switch forward for 5-10 seconds until the service mode message appears in dash display. The system will revert to normal operating mode, automatically, when you drive off.

    The owners manual contains a lengthy section on suspension operation and controls.

    3) Remove the front protective plastic shield beneath the engine to gain access to the radiator drain plug, located at the bottom right hand side of the radiator.

    Drain the engine coolant by unscrewing the blue slotted-head plastic drain plug. Leave the radiator cap on as you first open the drain. Have a flexible drain funnel and large capacity drain pan positioned beneath the drain to capture the coolant.

    Open the drain, then loosen the recovery jug fill cap slowly. This will drain the coolant more slowly so you dont have it everywhere!

    Then reinstall and hand tighten the drain plug. (Not too tight, snug will do!)

    Repair Steps

  • Address: 1000 Seville Road, Wa