Caz

0. Intro Removing the lining, spoiler, grille and other needed parts is not a simple task. Because you cannot remove any of these parts alone, you would have to remove the whole lot. This include sensor arrays, hoses, cable assemblies, a pump, the fog light and much more. To re-assemble some of these parts properly, you would need to buy additional replacement parts. We decided not to do all this. 1. Scope This tutorial, including photos, is based upon the work on a 9PA 2003 4.5L Cayenne S. It applies to the headlight washing assembly on the passenger side. This means the right side of your car, if your steering wheel is on the left. 2. Needed tools - nut set with TORX, preferably small to work inside the spoiler frame - PH1 philips scredriver, 30cm in length (important, needs to be very long and very thin) - a 2nd light to put inside the spoiler frame, preferably small - patience 3. Replacement parts (see pic.1) The available replacement part(s) are shown in pic. 1. Re-check them properly for your car model. If you need to buy the top cap (955 628 304 00) as new, note that it comes uncolored. You may try to get a used one in your car's color if you do not want to paint it yourself. 4. Preparation (see pic.2) - Make sure the key is in a position where you can still move the steering wheel. - Remove the headlight on the right side. It is decribed well in the car's manual. If you do not have a car's manual, search it via Google and download it as as a pdf. - Remove the wheel housing on the front, right side. It is a single piece. The screws are TORX. Expect dirt and dust. - When removed, take a look inside the front spoiler as shown in pic2. Identify the part shown in red. - Place the light in a position where it lights the whole area around the part shown in pic2. 5. Disassembly (see pic.3) - Gently pull away the clip marked in red on pic3 from the hose. Then pull off the hose. Expect fluid to pour out. - Remove the screws shown in pic3. Note that not all screws are visible from a single point of view. 6. Replacement (see pic.4) - Use the philips scredriver with 30cm length on the 3 screws shown in pic4. Note that one of the screws is not visible (this screw is photoshopped into pic4 to show you where it is). To get this hidden screw: - First remove the 2 visible ones. - Find a 2nd person to (gently) bend the plastic below the headlight to pull the assembly's lower side (the hose connector) to the back of the car. The screw should now become partly visible. - Let the 2nd person guide the 30cm screwdriver into position and hold it, while you turn the screw driver to remove the screw. This may take some approaches. Be patient. - Finally remove the faulty unit. 7. Re-assembly - Put the new unit into place. - Fix the hidden screw (we used a small amount of simple glue, magnetics did not suffice) to the 30cm screwdriver. - Use the 2nd person again to guide the screw into place. - Assemble the remaining screws shown in pic4. - Re-assemble the screws shown in pic3. - Reconnect the hose. When the clip is re-installed, the hose can not be pulled off anymore. Check this twice. - Re-install the headlight. - Make a quick test if the new washing assembly works. - Re-install the wheel housing. - Smile