Installing Rear Door Sub-Frame

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Rear Door Sub-Frame

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Move adjustable fastening elements to their home position.
Information

The screw elements have left-handed threads.
1. 1.1. Move the three adjustable fastening elements (-arrows A, B, C- ) on the door unit carrier to their home position. Screw the screw element -19- fully into the basic element -18- .
  
  Fig 2: Moving Three Adjustable Fastening Elements
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  Fig 3: Moving Screw Element
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Open basic door frame.
Engaging door unit carrier on basic door frame
1. 3.1. Push the plug connection inward through the door aperture and press in the rubber sleeve -10- from inside into the door aperture.
  
  Fig 4: Installing Rear Door Sub-Frame
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2. 3.2. Mount the door sub-frame -12- on the basic door frame -17- .
  
  Fig 5: Mounting Door Sub-Frame 12 On Basic Door Frame
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3. 3.3. Insert guide pins -13- and -16- into the holding slots -14- and -15- .
  
  Fig 6: Inserting Guide Pins 13 And 16 Into Holding Slots (1 Of 2)
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  Fig 7: Inserting Guide Pins 13 And 16 Into Holding Slots (2 Of 2)
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Fix door unit carrier to basic door frame, link up electrical plug connection and tighten lock.
1. 4.1. Fix the door sub-frame to the basic door frame by screwing in the fastening screws -9- and -11- . The fastening screws should only make light contact.
  
  Fig 8: Fixing Door Sub-Frame To Basic Door Frame
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  Fig 9: Locating Subframe Bolts
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2. 4.2. Connect electric push-on connector -6- .
  
  Fig 10: Installing Rear Door Sub-Frame
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3. 4.3. Press on the rubber sleeve -7- between the door and B-pillar.
  
  Fig 11: Installing Rear Door Sub-Frame
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 4.4. Screw in new fastening screws -3- on the door lock and tighten to the specified tightening torque. → Tightening torque: 20 Nm (15 ftlb.)-2 Nm (-1.5 ftlb.)
  
  Fig 12: Locating Door Lock Screw
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Adjust door unit carrier.
1. 5.1. The fastening screw -11- secures the front bearing position (holding slot -15- for guide pin -16- ). This bearing point cannot then be adjusted!
  
  Fig 13: Adjusting Door Unit Carrier
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2. 5.2. Close the door carefully.
  Information
  - The figures showing the gap dimensions can be found in the section entitled → Diagram of gap dimensions.
3. 5.3. The window frame (door sub-frame) must be adjusted with respect to the roof frame and B-pillar (-arrow D- ). The pivoting points in this case are the holding slots -14- , -15- and the guide pins -13- and -16- . Adjust the gap dimensions on the door sub-frame. → Test and adjustment value: 5 mm
  
  Fig 14: Locating Door Sub-Frame Gap Dimensions
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  Fig 15: Locating Window Frame (Door Sub-Frame) Guide Pins (1 Of 2)
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  Fig 16: Locating Window Frame (Door Sub-Frame) Guide Pins (2 Of 2)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 5.4. Tighten fastening screws -9, 11- to the specified tightening torque. → Tightening torque: 33 Nm (24 ftlb.)+/-3 Nm (+/-2 ftlb.)
  
  Fig 17: Locating Tighten Fastening Screws
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Fasten door unit carrier.
1. 6.1. Screw in fastening screws -8- and tighten to the specified tightening torque. → Tightening torque: 6 ftlb.+1.5 ftlb.
  
  Fig 18: Locating Door Unit Fastening Screws
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Clip in covers of front assembly openings.
1. 7.1. Clip in the top and bottom assembly opening covers -4- and -5- .
  
  Fig 19: Locating Assembly Opening Covers (1 Of 2)
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  Fig 20: Locating Assembly Opening Covers (2 Of 2)
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Clip in rear assembly opening covers and connecting KESSY wiring harness.
1. 8.1. For all vehicles:
  clip in the top and bottom assembly opening covers -1- and -2- .
  
  Fig 21: Locating Top And Bottom Assembly Opening Covers (1 Of 2)
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  Fig 22: Locating Top And Bottom Assembly Opening Covers (2 Of 2)
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2. 8.2. Also for vehicles with KESSY control module:
  Pull KESSY wiring harness in through the opening. Install rubber sleeve in the unit carrier until it engages completely (-arrow A- ).
  
  Insert connector into the socket (-arrow B- ) until it clicks into place.
  
  Fig 23: Inserting Connector Into Socket
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