ASSEMBLY INSTRUCTIONS TECHART daytime running lights for the TECHART Magnum up to MY 07
Part No. 048.180.150.009BLK TECHART daytime running lights, “black” Part No. 048.180.150.009CHR TECHART daytime running lights, "chrome"
ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
Contents I Important safety information ...... 3 II Preparation ...... 5 III Installation ...... 6 1 Prepare vehicle ...... 6 1.1 Switch off level control...... 6 2 Removing the Magnum front spoiler...... 7 3 Installing the TECHART daytime running light ...... 9 3.1 Installing the TECHART daytime running light ...... 9 3.2 Installing the TECHART control unit...... 11 3.3 Installing the TECHART wiring harness ...... 12 3.4 Fitting the TECHART Magnum front spoiler to the front panel...... 15 4 Performing final work on the vehicle...... 15 4.1 Finishing touches...... 15 4.2 Final inspection...... 15
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
I Important safety information
All of the necessary work must be performed by qualified persons with an appropriate level of expertise.
Vehicle lifts with an insufficient lifting capacity can collapse under the weight of the vehicle and crush any persons standing underneath.
Compare the weight of the vehicle with the lifting capacity of your vehicle lift. The weight of the vehicle must not exceed the lifting capacity of your vehicle lift. The weight of the vehicle can be found in the vehicle operating manual.
Risk of injury from electric current.
Switch off the ignition and disconnect the battery when working on the vehicle electrical/electronics systems.
Risk of fire and explosion from ignition of windshield cleaning agents/antifreeze and their vapors.
Risk of poisoning from ingesting windshield cleaning agents/antifreeze and breathing in their vapors.
Risk of injury due to irritation caused by windshield cleaning agents/antifreeze coming into contact with eyes, skin and other parts of the body.
Wear protective clothing and safety glasses. Avoid naked flames, fire and sources of ignition. Avoid contact with eyes, skin and other parts of the body. Do not eat, drink or smoke when handling windshield cleaning agents/antifreeze. Do not breathe in vapors and ensure adequate ventilation.
Keep windshield cleaning agents/antifreeze only store them in sealable original containers.
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
Risk of injury from hands and arms being crushed, cut or lacerated when
working with sharp-edged and bulky objects.
Wear protective clothing and protective gloves. Keep limbs out of narrow and inaccessible areas of the vehicle and/or avoid dangerous situations by using special tools and suitable aids.
Risk of injury to back, muscles, joints, tendons and ligaments from lifting and carrying heavy and/or bulky objects.
Lift and transport heavy and/or bulky objects with the help of other people and/or with suitable aids.
Before starting the assembly procedure, carefully read the assembly instructions in full and pay attention to the safety information and sequence of the individual operation steps.
All body parts must be prepared and painted in accordance with the attached painting guide.
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
II Preparation
Number of people required
At least two people are required to install this product.
Help and support
If you have any technical queries, please contact us immediately: [email protected]
Check the parts kit of the TECHART multifunctional daytime running lights
1 048.180.150.009 TECHART daytime running lights Consisting of: 1 048.180.159.100BLK Right-hand daytime running light, “black” 1 048.180.159.101BLK Left-hand daytime running light, “black” or 1 048.180.159.100CHR Right-hand daytime running light, “chrome” 1 048.180.159.101CHR Left-hand daytime running light, “chrome” 2 000.180.185.009 Control unit 1 087.180.100.500-01 Wiring harness 4 0039004.8X1310025 Sheet metal bolt, binding head with flange 4.8x13, black 4 0029004.8/19.0X12 Sheet metal nut 4.8/19.0x12.7 10 000.590.502.221 Cable tie 3.5x140 mm, black 1 000590555976 Flat fuse holder 1 000590731020 Flat fuse, 20 A, yellow 2 000.590.555.5162 Watertight crimp connector, blue, 1.5 - 2.5 mm² 3 000.590.555.5161 Watertight crimp connector, red, 0.5 - 1.0 mm² 1 00091089010031 Klebt + Dichtet (adhesive sealant) black, 70 ml tube
Use the table to check whether all of the required parts are present. Please contact us immediately if any parts are missing: [email protected] Once parts have been removed from their original packaging, ensure that they are properly handled and stored.
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
III Installation
1 Prepare vehicle
i Before starting work, check that the vehicle is free of defects. Use the PIWIS system tester to read out all of the fault memories of the individual vehicle components and first rectify any faults displayed.
1.1 Switch off level control 1.
1 Set the vehicle to normal level.
2 Switch on the ignition.
3 Press the rocker switch forwards for 5 - 10 seconds.
i The following message is displayed on the multifunction display of the instrument panel: "Control switched off".
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
2 Removing the Magnum front spoiler
i Also refer to Porsche Cayenne operating manual.
Fig. 01
1 Open the engine hood.
2 Remove the main headlamps.
3 Unscrew the upper mounting bolts.
4 Using a screwdriver, lever out the plugs and remove (see arrows).
Fig. 02
5 Remove the mounting bolts (4x) from the front apron from below (see arrows).
6 Detach the inner wheelhouse liner from the front spoiler.
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
7 Unscrew the mounting bolts (1) from the wheelhouse (2 bolts on each side).
8 Disconnect the electrical connector (4) and water hose (2) in the right-hand wheelhouse.
i Water may run out when the water hose is disconnected. Collect the water in a suitable receptacle.
9 Detach the lamp sockets (3) for left and right side turn signals.
10 Disconnect the high beam headlamp in the wheelhouse.
Fig. 03
11 Unscrew the TECHART Magnum front spoiler in the headlamp cutout (see arrow).
12 Remove the TECHART Magnum front spoiler by pulling forwards.
Fig. 04
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
3 Installing the TECHART daytime running light
3.1 Installing the TECHART daytime running light
1 Unscrew the two original outer grilles (6).
Fig. 05 Fig. 06
2 Mark the back of the original grilles (6), then cut (see illustration):
• Cut 1 (S1) parallel to 4th bar from bottom, 28 mm • Cut 2 (S2) parallel to 4th bar from bottom, 61 mm • Cut 3 (S3) measured at bar, from inside corner, 41 mm • Cut 4 (S4) parallel to cut 3, 239 mm • Cut 5 (S5) parallel to cut 2, 33 mm • Chamfer: One chamfer in each of the two upper corners, 5x5 mm
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ASSEMBLY daytime running lights INSTRUCTIONS
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Fig. 07 Fig. 08
3 Grind the corners of the upper bar until they are even (see arrows).
i When grinding, take care not to damage the uncovered surface.
i The bonding surfaces on the TECHART trim panels and the original grilles must be dry and free from dust or paint spray mist! Use cleaning agent to thoroughly degrease bonding surfaces on the TECHART trim panels and original grilles. Do not touch the surfaces after they have been cleaned.
i Important! Take care not to drill through the TECHART daytime running light when drilling. Pay attention to the gap dimensions when aligning the TECHART daytime running light.
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
4 Mark the dimensions for fastening the TECHART daytime running light on the grille and drill to d = 2 mm.
• Dimension 1 = 6 mm (M1) to rear edge of top bar, parallel • Dimension 2 = 38 mm (M2) parallel to cut 3 • Dimension 3 = 5 mm (M3) parallel to cut 4 • Dimension 4 = 11 mm (M4) parallel to cut 5 Fig. 09
5 Insert the trim panel in the original grille.
6 Secure the TECHART daytime running light with 2.9x13 bolts. Parallel distance from 4th bar from bottom 24 mm.
7 Bond to several points from the back using PU adhesive.
i Figure 10 shows the dimensions on the right-hand original grille. Please note that the dimensions on the left-hand original grill will be the other way round.
3.2 Installing the TECHART control unit
1 Position the TECHART control unit 000.180.185.009 (17) above the impact protector between the air ducts.
2 Secure the TECHART control unit with bolts 5x16.
Fig. 10
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
3.3 Installing the TECHART wiring harness
i Switch off the ignition and disconnect the battery when working on the vehicle electrical/electronic systems. After crimping, heat up all crimp connectors using a hot air gun so that they form a watertight seal.
1 Route the TECHART wiring harness 087.180.100.500-01 (20) from right to left via the central air duct. The red cable with the 1-way connector is routed to the left- hand side.
2 Connect the red cable of the TECHART wiring harness for terminal 15 to the fuse box (left in direction of travel in the bulkhead). Proceed as follows:
• Completely unscrew the cover. • Cut the cable of the red connector pin 8 = terminal 15 approx. 20 mm from the connector. • Strip both ends. • Route the red cable of the TECHART wiring harness 087.180.10.500-01 into the fuse box and strip both ends. • Connect the TECHART fuse holder to the 20 A fuse via the blue watertight crimp connector and the red cable of the wiring harness. • Connect the other end of the TECHART fuse holder to the cable in the fuse box pin 8 using the watertight crimp connector and suitable crimping pliers. • Secure the fuse holder in the fuse box using cable ties. • Screw the cover back on.
3 Connect the 3-way connector of the TECHART wiring harness to the TECHART control unit.
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
On the right 4 Remove the main headlamp connector from the headlamp bracket.
5 Cut the yellow/red cable (parking light cable, positive), pin 4 in vehicles with Xenon, pin 1 without Xenon, approx. 20 mm from the connector (9).
6 Connect the gray cable of the TECHART wiring harness (20) to the original wiring harness using the red crimp connector and the Fig. 11 yellow/red cable. The parking light cable will stay unconnected.
7 Next, reinstall the connector in the headlamp bracket.
8 Route cables cleanly and secure with cable ties.
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
On the left 9 Remove the main headlamp connector from the headlamp bracket.
10 Cut the black/blue cable (parking light cable, positive), pin 4 in vehicles with Xenon, pin 1 without Xenon, approx. 20 mm from the connector (9).
11 Connect the gray cable of the TECHART wiring harness (20) to the original wiring harness using the red crimp connector and the Fig. 12 black/blue cable. The parking light cable will stay unconnected.
12 Cut the brown cable pin 10 1.5 mm² (ground) approx. 20 mm from the connector (9).
13 Connect the black cable of the TECHART wiring harness to the original wiring harness using the blue crimp connector and the brown cable, and affix the connector.
14 Next, reinstall the connector in the headlamp bracket.
15 Route cables cleanly and secure with cable ties.
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
3.4 Fitting the TECHART Magnum front spoiler to the front panel
1 Slide the complete front spoiler into the original guides on the vehicle and screw to the original attachment points.
2 Also screw into the headlamp cutout.
3 In the right wheelhouse, connect the electrical connector and water hose for the headlamp cleaning system.
4 Bolt the wheelhouse liners back on.
5 Connect the high beam headlamps.
i Pay attention to the gap dimensions when aligning the TECHART Magnum front spoiler.
4 Performing final work on the vehicle 4.1 Finishing touches
Switch on the level control
1 Switch on the ignition.
2 Press the rocker switch forwards for 5 - 10 seconds.
i The following message is displayed on the multifunction display of the instrument panel: “Control switched on”.
4.2 Final inspection
1 Perform a general function test of the vehicle.
i Read out all of the fault memories of the individual vehicle components using the PIWIS Porsche system tester, erase any fault messages displayed and/or rectify faults.
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ASSEMBLY daytime running lights INSTRUCTIONS
TECHART daytime running lights
TECHART AUTOMOBILDESIGN GMBH RÖNTGENSTRASSE 47 D-71229 LEONBERG / GERMANY TEL +49 (0) 7152 / 9339- 0 FAX +49 (0) 7152 / 9339-33 [email protected] www.techart.de
E&O excepted. Subject to change at any time without prior notice. Copyright 2008 by TECHART Automobildesign GmbH
Version 01/2010 Artikel-Nr./Part No. 048.180.150.099
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