Porsche Cayenne Turbo (9PA) Technical Service Bulletin # 633/08 Date: 090716
Body - Roof Box Assembly And Usage
6
Cayenne (9PA)
Instructions 33/08 ENU 6692
Jul 16, 2009
Roof Box,Wide (520 Liter)
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 27
Vehicle Type:
Cayenne/S/GTS/T (1st & 2nd Generations)
Model Year:
As of 2003
INFORMATION:
Instructions for assembly and use
NOTE:
The Cayenne must be equipped with the roof transport system or roof rails w/cross bars before this roof box accessory can be installed ( -> Figure 1
).
The roof box:
- was tested and adapted to suit the vehicles.
- increases the luggage space of the vehicle by approx. 520 liters.
- can be opened from either longitudinal side.
- design has been optimized to minimize drag and wind noise.
- has a safety closing system. The key can only be removed when the lid of the roof box is closed properly, i.e. all six closing points are closed
and the key is at the "locked" position.
Parts Info:
955.044.002.12 -> Roof box, wide
Parts List:
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 28
NOTE:
The keys (-> Figure 2 -2-) can be re-ordered if lost by specifying the part number and the code "Nxxx" (possible codes range from N001 to N200)
specified on the lock cylinder.
Technical Data:
Max. length: approx. 2,180 mm Max. width: approx. 895 mm
Max. height: approx. 400 mm Empty weight: 57 lbs (26 kg)(1)
(1) Observe permissible load for the roof transport system or roof rails (-> Owner's Manual, chapter on Weights).
DANGER:
Roof box must be secured properly to prevent it from falling off
- Danger of accidents (death/danger to yourself and/or other road users)
- Regularly check the roof box before each trip and during an extended trips to ensure that it is seated properly and securely on the
vehicle.
Change in vehicle handling due to higher center of gravity, roof load and larger area exposed to the wind
- Danger of accidents (death/danger to yourself and/or other road users)
- Adapt driving style accordingly.
- Observe speed regulations and general information on the topic "Roof transport system" in the Owner's Manual.
- If the roof box is not in use, it should be completely removed from the vehicle in the interest of driving comfort (noise level) and
fuel economy.
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 29
Work Procedure:
1. Preparatory work
1.1 Position bracket for roof transport system ( -> Instructions for using roof transport system and labor operation no. 669223).
1. 1. 1 Open side roof transport system caps on the roof transport system bracket.
1. 1. 2 Vehicles without standard roof rails have two guide rails along the length of the vehicle roof with six small grooves in each ( ->
Figure 3 -A1 to A6-).
Slide the front bracket as far as the very first groove ( -> Figure 3 -A1-) in the guide rail.
You will feel slight resistance and hear a click at this position.
1. 1. 3 Decide which side (driver's or passenger's side) you want to fit the roof box on and close the cap on the bracket on the opposite
side.
This secures the bracket and prevents it from moving lengthways.
1. 1. 4 Slide the rear bracket as far as the second groove (-> Figure 3 -A4-) after the large cut-out in the guide rail.
You will feel slight resistance and hear a click at this position.
1. 1. 5 Close the cap on the bracket on the same side as on the front bracket.
This secures the bracket and prevents it from moving lengthways.
1. 1. 6 Check gap X between the brackets (-> Figure 3 -B-). Gap X ~ 80 cm
1.2 Position roof rail cross bars (-> Instructions for using roof rail cross bars and labor operation no. 669223).
1. 2. 1 Loosen front cross bar if necessary and fit loosely in the B-pillar area leaving gap A (-> Figure 4 -A-) with respect to the seam in
the roof rails. Gap A ~ 2.5 cm
1. 2. 2 Loosen rear cross bar if necessary and fit loosely in the C-pillar area leaving gap B (-> Figure 4 -B-) with respect to the seam in
the roof rails. Gap B ~ 15.0 cm
1. 2. 3 Check gap X (-> Figure 4 -X-) between the brackets. Gap X ~ 80 cm
1. 2. 4 Bolt both cross bars securely to the roof rails.
1. 2. 5 Decide which side (driver's or passenger's side) you want to fit the roof box on and close the caps on the opposite side.
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 30
1.3 Prepare roof box for mounting
INFORMATION: When opening, make sure that the opposite lock is locked.
1. 3. 1 Unpack the roof box and unlock it with one of the keys supplied. Turn the key clockwise to do this.
1. 3. 2 Move all four perforated strips (-> Figure 5 -1-) into the guides ( -> Figure 5 -2-) so that the centre slot ( -> Figure 5 -3-) is
centered in the cut-out on the guide.
1. 3. 3 Check that the rubber seal ( -> Figure 5 -4-) is seated and positioned correctly on the underside of the clamp (-> Figure 5 -5-)
and adjust it if necessary.
1. 3. 4 Insert an M8 T-bolt ( -> Figure 5 -6-) into the center slot from below and fit a clamp ( -> Figure 5 -5-) onto the thread.
1. 3. 5 Loosely fit M8 butterfly nut ( -> Figure 5 -7-).
1. 3. 6 When fitting the remaining three clamps, make sure that the lashing points on the top ( -> Figure 6 -1-) are aligned forward and
backward symmetrically with respect to the driver's or passenger's side.
CAUTION:
Risk of damage to the load or to the roof box if
- profile rails (ski supports) are not secured.
- Never transport profile rails (ski supports) in the roof box unsecured. Always fasten them as described in the instructions for use.
1.4 Fit the two ski supports (if necessary).
1. 4. 1 Position the M8 x 45 hexagon-head bolt ( -> Figure 7 -1-) into the sliding block (plastic, -> Figure 7 -2-) with the bolt head flush
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 31
( -> Figure 7 -A-). Guide the (plastic) sliding block together with the M8 x 45 hexagon-head bolt into the groove on the
underside of the ski support ( -> Figure 7 -3-, -> Figure 7 -B-).
Fit the remaining sliding blocks in the same way.
1. 4. 2 Align the two sliding blocks (underside of ski support) with respect to the width of the slots (guide rail) in the roof box floor ( ->
Figure 8 -A, arrows-).
1. 4. 3 Position thread of M8 hexagon-head bolt on the desired breaking point in the perforated strip ( -> Figure 8 -A, inset-).
1. 4. 4 Carefully press the ski support with the thread of the M8 hexagon-head bolt into the perforated strip ( -> Figure 8 -B-) until the
ski support is positioned on the guide rail.
1. 4. 5 Secure the ski support to the underside of the roof box with two M8 butterfly nuts ( -> Figure 8 -C-).
1. 4. 6 Fit the second ski support in the same way.
1.5 Lock the roof box.
CAUTION:
Incorrect fitting, use or care of the roof box
- Risk of damage to the roof of the vehicle, rear lid and/or roof box
- Since the roof box is large, it should always be installed and removed from the roof transport system by two people.
- Open the roof box only if the opposite lock is locked.
- Remove the roof box from the roof of the vehicle before washing the vehicle in an automatic car wash.
- Keep in mind the new overall vehicle height when driving through tunnels or under low branches and when entering garages and
multi-story parking garages.
- Clean the roof box using soapy water only (without alcohol, chlorine or ammonia additives); other substances could attack and
damage the surface.
- Do not put stickers on the roof box. The adhesive film can dissolve the surface of the roof box or cause tension cracks.
- Occasionally spray the locks of the roof box with a commercially available spray lubricant. The lubricant must not come into
contact with the plastic surface of the roof box.
- When opening the rear lid for the first time,make sure there is sufficient space between the rear lid and the installed roof box.
Move the roof box forward in direction of travel if necessary.
2. Fitting the roof box on the transport system
2.1 Position the roof box on the brackets from the side of the vehicle on which the brackets for the roof transport system are open.
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 32
2.2 Check and, if necessary, align the positions of the two closest sliding blocks (on the M8 x 55 T-bolt -> Figure 9 -A1-) with respect to the
slots in the brackets ( -> Figure 9 -A2-).
INFORMATION:
ONLY for vehicles with roof rails:
During installation, make sure there is enough space between the floor of the roof box and the upper edge of the roof rails (-> Fig. 9 -B-).
Reposition roof rail cross bars if necessary.
2.3 Insert the sliding blocks for the roof box into the groove on the brackets and carefully slide the roof box to the center of the vehicle.
Adjust the position of the last two sliding blocks (T-bolts) if necessary.
2.4 Align the roof box symmetrically with respect to the center of the vehicle ( -> Figure 10 -arrows-) and close the side caps on the brackets
( -> Figure 10).
2.5 Carefully open the rear lid of the vehicle and check the gap between the rear lid and roof box ( -> Figure 11 ).
Adjust the gap as required by moving the roof box forward lengthwise or by changing the opening angle of the rear lid (see Step 2.7).
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 33
2.6 Open the roof box on alternate sides and tighten the four M8 butterfly nuts.
When doing this, make sure the pin and seal (underside of clamp) are seated correctly in the perforated strip (see Step 1.3).
2.7 Only for vehicles with electric rear lid (I-no. 4E7): Set the opening angle (opening height) of the rear lid (-> Cayenne Owner's Manual,
all; section entitled "Setting the opening height of the rear lid").
DANGER:
Incorrect loading of the roof box
- Danger of accidents (death/danger to yourself and/or other road users)
- Load the roof box so that the load is distributed uniformly in the roof box.
- If a second attachment system installed, the roof box should be far enough away from the adjacent system so that the two cannot
bump against each other during the trip.
- Secure load sufficiently to prevent it from shifting during the trip.
- Observe the maximum permissible roof load of the vehicle in accordance with the Owner's Manual.
- Always load the roof box from the side of the road (e.g. pavement).
3. Loading the roof box
3.1 Feed the tension strap ( -> Figure 12 -1-) through the eyelets on the floor of the roof box ( -> Figure 12 -2-) or on the clamps ( -> Figure
12 -3-).
Fit other tension straps in the same way, if necessary.
3.2 Load the roof box and secure the load with tension straps.
INFORMATION: Make sure there is enough space between the attachment point for skis and the floor or lid ( -> Fig. 12 -arrow-) of the roof
box. Reposition skis in the roof box if necessary.
3.3 Carefully close the lid of the roof box.
INFORMATION: The key can be removed only if the roof box is locked.
3.4 Lock the roof box by turning the key counter-clockwise and remove the key.
INFORMATION: Please pass all this information on to the customer as well.
4. Remove the roof box from the roof transport system
4.1 Open the roof box and empty it completely.
4.2 Loosen the four M8 butterfly nuts slightly.
4.3 Open the side caps on each end of the brackets (-> Instructions for using the roof transport system and labor operation no. 669223 or
Instructions for using roof rail cross bars and labor operation no. 669223).
4.4 Together with a second person, carefully pull the roof box sideways out of the roof transport system brackets and remove it from the
vehicle.
4.5 Lock the roof box, clean it if necessary (observe warning) and store it lying flat in a suitable location.
4.6 Close the side caps on the end of the brackets (see relevant instructions for use).
Working Times:
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 34
Disclaimer
Body - Roof Box Assembly And Usage
6
Cayenne (9PA)
Instructions 33/08 ENU 6692
Jul 16, 2009
Roof Box,Wide (520 Liter)
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 27
Vehicle Type:
Cayenne/S/GTS/T (1st & 2nd Generations)
Model Year:
As of 2003
INFORMATION:
Instructions for assembly and use
NOTE:
The Cayenne must be equipped with the roof transport system or roof rails w/cross bars before this roof box accessory can be installed ( -> Figure 1
).
The roof box:
- was tested and adapted to suit the vehicles.
- increases the luggage space of the vehicle by approx. 520 liters.
- can be opened from either longitudinal side.
- design has been optimized to minimize drag and wind noise.
- has a safety closing system. The key can only be removed when the lid of the roof box is closed properly, i.e. all six closing points are closed
and the key is at the "locked" position.
Parts Info:
955.044.002.12 -> Roof box, wide
Parts List:
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 28
NOTE:
The keys (-> Figure 2 -2-) can be re-ordered if lost by specifying the part number and the code "Nxxx" (possible codes range from N001 to N200)
specified on the lock cylinder.
Technical Data:
Max. length: approx. 2,180 mm Max. width: approx. 895 mm
Max. height: approx. 400 mm Empty weight: 57 lbs (26 kg)(1)
(1) Observe permissible load for the roof transport system or roof rails (-> Owner's Manual, chapter on Weights).
DANGER:
Roof box must be secured properly to prevent it from falling off
- Danger of accidents (death/danger to yourself and/or other road users)
- Regularly check the roof box before each trip and during an extended trips to ensure that it is seated properly and securely on the
vehicle.
Change in vehicle handling due to higher center of gravity, roof load and larger area exposed to the wind
- Danger of accidents (death/danger to yourself and/or other road users)
- Adapt driving style accordingly.
- Observe speed regulations and general information on the topic "Roof transport system" in the Owner's Manual.
- If the roof box is not in use, it should be completely removed from the vehicle in the interest of driving comfort (noise level) and
fuel economy.
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 29
Work Procedure:
1. Preparatory work
1.1 Position bracket for roof transport system ( -> Instructions for using roof transport system and labor operation no. 669223).
1. 1. 1 Open side roof transport system caps on the roof transport system bracket.
1. 1. 2 Vehicles without standard roof rails have two guide rails along the length of the vehicle roof with six small grooves in each ( ->
Figure 3 -A1 to A6-).
Slide the front bracket as far as the very first groove ( -> Figure 3 -A1-) in the guide rail.
You will feel slight resistance and hear a click at this position.
1. 1. 3 Decide which side (driver's or passenger's side) you want to fit the roof box on and close the cap on the bracket on the opposite
side.
This secures the bracket and prevents it from moving lengthways.
1. 1. 4 Slide the rear bracket as far as the second groove (-> Figure 3 -A4-) after the large cut-out in the guide rail.
You will feel slight resistance and hear a click at this position.
1. 1. 5 Close the cap on the bracket on the same side as on the front bracket.
This secures the bracket and prevents it from moving lengthways.
1. 1. 6 Check gap X between the brackets (-> Figure 3 -B-). Gap X ~ 80 cm
1.2 Position roof rail cross bars (-> Instructions for using roof rail cross bars and labor operation no. 669223).
1. 2. 1 Loosen front cross bar if necessary and fit loosely in the B-pillar area leaving gap A (-> Figure 4 -A-) with respect to the seam in
the roof rails. Gap A ~ 2.5 cm
1. 2. 2 Loosen rear cross bar if necessary and fit loosely in the C-pillar area leaving gap B (-> Figure 4 -B-) with respect to the seam in
the roof rails. Gap B ~ 15.0 cm
1. 2. 3 Check gap X (-> Figure 4 -X-) between the brackets. Gap X ~ 80 cm
1. 2. 4 Bolt both cross bars securely to the roof rails.
1. 2. 5 Decide which side (driver's or passenger's side) you want to fit the roof box on and close the caps on the opposite side.
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 30
1.3 Prepare roof box for mounting
INFORMATION: When opening, make sure that the opposite lock is locked.
1. 3. 1 Unpack the roof box and unlock it with one of the keys supplied. Turn the key clockwise to do this.
1. 3. 2 Move all four perforated strips (-> Figure 5 -1-) into the guides ( -> Figure 5 -2-) so that the centre slot ( -> Figure 5 -3-) is
centered in the cut-out on the guide.
1. 3. 3 Check that the rubber seal ( -> Figure 5 -4-) is seated and positioned correctly on the underside of the clamp (-> Figure 5 -5-)
and adjust it if necessary.
1. 3. 4 Insert an M8 T-bolt ( -> Figure 5 -6-) into the center slot from below and fit a clamp ( -> Figure 5 -5-) onto the thread.
1. 3. 5 Loosely fit M8 butterfly nut ( -> Figure 5 -7-).
1. 3. 6 When fitting the remaining three clamps, make sure that the lashing points on the top ( -> Figure 6 -1-) are aligned forward and
backward symmetrically with respect to the driver's or passenger's side.
CAUTION:
Risk of damage to the load or to the roof box if
- profile rails (ski supports) are not secured.
- Never transport profile rails (ski supports) in the roof box unsecured. Always fasten them as described in the instructions for use.
1.4 Fit the two ski supports (if necessary).
1. 4. 1 Position the M8 x 45 hexagon-head bolt ( -> Figure 7 -1-) into the sliding block (plastic, -> Figure 7 -2-) with the bolt head flush
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 31
( -> Figure 7 -A-). Guide the (plastic) sliding block together with the M8 x 45 hexagon-head bolt into the groove on the
underside of the ski support ( -> Figure 7 -3-, -> Figure 7 -B-).
Fit the remaining sliding blocks in the same way.
1. 4. 2 Align the two sliding blocks (underside of ski support) with respect to the width of the slots (guide rail) in the roof box floor ( ->
Figure 8 -A, arrows-).
1. 4. 3 Position thread of M8 hexagon-head bolt on the desired breaking point in the perforated strip ( -> Figure 8 -A, inset-).
1. 4. 4 Carefully press the ski support with the thread of the M8 hexagon-head bolt into the perforated strip ( -> Figure 8 -B-) until the
ski support is positioned on the guide rail.
1. 4. 5 Secure the ski support to the underside of the roof box with two M8 butterfly nuts ( -> Figure 8 -C-).
1. 4. 6 Fit the second ski support in the same way.
1.5 Lock the roof box.
CAUTION:
Incorrect fitting, use or care of the roof box
- Risk of damage to the roof of the vehicle, rear lid and/or roof box
- Since the roof box is large, it should always be installed and removed from the roof transport system by two people.
- Open the roof box only if the opposite lock is locked.
- Remove the roof box from the roof of the vehicle before washing the vehicle in an automatic car wash.
- Keep in mind the new overall vehicle height when driving through tunnels or under low branches and when entering garages and
multi-story parking garages.
- Clean the roof box using soapy water only (without alcohol, chlorine or ammonia additives); other substances could attack and
damage the surface.
- Do not put stickers on the roof box. The adhesive film can dissolve the surface of the roof box or cause tension cracks.
- Occasionally spray the locks of the roof box with a commercially available spray lubricant. The lubricant must not come into
contact with the plastic surface of the roof box.
- When opening the rear lid for the first time,make sure there is sufficient space between the rear lid and the installed roof box.
Move the roof box forward in direction of travel if necessary.
2. Fitting the roof box on the transport system
2.1 Position the roof box on the brackets from the side of the vehicle on which the brackets for the roof transport system are open.
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 32
2.2 Check and, if necessary, align the positions of the two closest sliding blocks (on the M8 x 55 T-bolt -> Figure 9 -A1-) with respect to the
slots in the brackets ( -> Figure 9 -A2-).
INFORMATION:
ONLY for vehicles with roof rails:
During installation, make sure there is enough space between the floor of the roof box and the upper edge of the roof rails (-> Fig. 9 -B-).
Reposition roof rail cross bars if necessary.
2.3 Insert the sliding blocks for the roof box into the groove on the brackets and carefully slide the roof box to the center of the vehicle.
Adjust the position of the last two sliding blocks (T-bolts) if necessary.
2.4 Align the roof box symmetrically with respect to the center of the vehicle ( -> Figure 10 -arrows-) and close the side caps on the brackets
( -> Figure 10).
2.5 Carefully open the rear lid of the vehicle and check the gap between the rear lid and roof box ( -> Figure 11 ).
Adjust the gap as required by moving the roof box forward lengthwise or by changing the opening angle of the rear lid (see Step 2.7).
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 33
2.6 Open the roof box on alternate sides and tighten the four M8 butterfly nuts.
When doing this, make sure the pin and seal (underside of clamp) are seated correctly in the perforated strip (see Step 1.3).
2.7 Only for vehicles with electric rear lid (I-no. 4E7): Set the opening angle (opening height) of the rear lid (-> Cayenne Owner's Manual,
all; section entitled "Setting the opening height of the rear lid").
DANGER:
Incorrect loading of the roof box
- Danger of accidents (death/danger to yourself and/or other road users)
- Load the roof box so that the load is distributed uniformly in the roof box.
- If a second attachment system installed, the roof box should be far enough away from the adjacent system so that the two cannot
bump against each other during the trip.
- Secure load sufficiently to prevent it from shifting during the trip.
- Observe the maximum permissible roof load of the vehicle in accordance with the Owner's Manual.
- Always load the roof box from the side of the road (e.g. pavement).
3. Loading the roof box
3.1 Feed the tension strap ( -> Figure 12 -1-) through the eyelets on the floor of the roof box ( -> Figure 12 -2-) or on the clamps ( -> Figure
12 -3-).
Fit other tension straps in the same way, if necessary.
3.2 Load the roof box and secure the load with tension straps.
INFORMATION: Make sure there is enough space between the attachment point for skis and the floor or lid ( -> Fig. 12 -arrow-) of the roof
box. Reposition skis in the roof box if necessary.
3.3 Carefully close the lid of the roof box.
INFORMATION: The key can be removed only if the roof box is locked.
3.4 Lock the roof box by turning the key counter-clockwise and remove the key.
INFORMATION: Please pass all this information on to the customer as well.
4. Remove the roof box from the roof transport system
4.1 Open the roof box and empty it completely.
4.2 Loosen the four M8 butterfly nuts slightly.
4.3 Open the side caps on each end of the brackets (-> Instructions for using the roof transport system and labor operation no. 669223 or
Instructions for using roof rail cross bars and labor operation no. 669223).
4.4 Together with a second person, carefully pull the roof box sideways out of the roof transport system brackets and remove it from the
vehicle.
4.5 Lock the roof box, clean it if necessary (observe warning) and store it lying flat in a suitable location.
4.6 Close the side caps on the end of the brackets (see relevant instructions for use).
Working Times:
2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 34
Disclaimer