Removing and Installing Front Spring Strut (Air Spring)

Removing and installing front spring strut (air spring)
The air springs are installed as standard in the Cayenne Turbo and are optional in the Cayenne S. The steel springs do not apply for the Cayenne Turbo.








Tools

Removal

Caution! Danger of injury and material damage if the wheel carrier is raised incorrectly.
^ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When raising, use a suitable intermediate layer (hard rubber).
^ Do not damage the brake cover plate.

When fitting/removing the air-spring strut, the drive shaft is removed and installed.
1. Open bonnet, remove cowl panel cover and respective side engine compartment lining. To do this, the windscreen wiper arms must be removed.
2. Remove hub cap using puller hook 9229/1 and undo drive shaft fastening at the side of the wheel before raising the vehicle. Operate the brake whilst doing so (2 workers required).
3. Raise vehicle.





4. To bleed the level control system (air pressure must be allowed to escape out of system), use the Porsche System Tester. To do this, select the Bleed level control menu item in the Level control system.





5. Lift wheel carrier carefully to facilitate removal. Use a suitable -lift with rubber base- in order to prevent slipping.





6. Undo pressure pipe on the residual pressure restraint valve with an open-ended wrench.





7. Separate -compact connector (in wheel housing on side member)- and the wheel acceleration sensor and level sensor plug connections.





8. Remove -connecting rod- using the lift to support the wheel carrier (assembly aid).





9. Fix upper axle strut with tension jack VW 552. This involves tensioning axle strut slightly because top ball joint can otherwise get damaged. When doing this, insert -tension jack- into the top opening of wheel house (double panel, under the wheel housing cover) and into the axle strut. This is only necessary if the same control arm is re-installed.





10. Remove lower spring strut and undo -brake caliper-.
11. Push protective tube over drive shaft. Release drive shaft at transmission flange and lay down carefully. Use suitable base for front axle carrier.





12. Push (press through) peg of drive shaft by approximately 20 - 25 mm into the wheel hub using universal drive shaft/wheel hub extractor 87-1.





13. Remove the two holders (brake hose, combination wire) on wheel carrier and let them hang.
14. Remove respective outermost -tie rod end- with press-gut tool T10187. When pressing out, screw fastening nut on flush (protects the ball joint thread).





15. Press out -ball joint of top axle strut- of wheel carrier with press-out tool T10187.





16. Take out tension jack.
17. Remove brake caliper fastening screws and hang -brake caliper- in a suitable place in the wheel well.
18. Remove drive shaft. To do this, first worker must pull top wheel carrier outwards carefully. Second worker must pull out drive shaft carefully.





19. Remove the 3 securing mechanisms of spring strut in the engine compartment (2 securing points in front of the radiator tank, 1 securing point inside the radiator tank). The 3 securing mechanisms are shown here from inside the wheel well (wheel carrier installed).





20. Pull out spring strut carefully.

Installation

Caution! When filling the air-spring struts, the vehicle lifts.
Danger of injury and material damage if the wheel carrier is raised incorrectly.
^ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When raising, use a suitable intermediate layer (hard rubber).
^ Do not damage the brake cover plate.
^ The level sensor(s) must be calibrated following repairs.

Note!
^ Visually inspect all parts.
^ If a new spring strut is fitted, it must be prebilled to 3 bar in its original packaging.
^ Replace self-locking nuts.
^ Replace all expansion screws (screws which are fitted with torque angle tightening procedure).





^ The entire threaded parts of the axle must be tightened in vehicle position. Vehicle position means: vehicle standing on the wheels, or the wheel suspension is raised using a universal vehicle lift. -Dimension X-, from lower edge of wing to middle of axle 502 mm ± 10 mm corresponds to vehicle position.





^ Use an -intermediate layer (hard rubber)-. Do not damage the brake cover plate.
^ When fitting the ball joints, ensure that the bevel pinions are clean! Remove dirt or grease on bevel pinions, e.g. with a lint-free cloth. Do not use cleaning agent/solvent.
^ Use correct tightening torques.





1. Retract -spring strut- carefully, position with the auxiliary pins and tighten onto the shaft bolt to the prescribed tightening torque.
2. Fit drive shaft. To do this, first worker must pull top wheel carrier outwards carefully. Second worker must retract drive shaft carefully.
3. Fit brake caliper on wheel carrier (do not tighten brake caliper fastening screws yet).





4. Mount wheel carrier on upper axle strut. When doing this, observe drive shaft clearance (use suitable base). To facilitate fitting and so that the upper ball pin does not fall into the stop, raise the wheel carrier slightly with a suitable lift to enable the upper ball pin to be inserted. Use a -lift with rubber base- in order to prevent slipping.





5. Insert tension jack and slightly tension upper axle strut.
6. Fit fastening pin for lower spring strut. Remove tension jack.





7. Grease mounting-face ring of axle nut with a little Optimoly TA aluminum paste. Screw on axle nut in order to prevent shaft from slipping out. If it is not possible to push shaft in all the way, use assembly fixture T10206 to pull drive shaft in. Remove protective tube and base.
8. Mount drive shaft on transmission flange and tighten brake caliper fastening screws.





9. Fit connecting rod.





10. Position -compact connector in wheel well-. Fit holder for brake hose/combination wire at the top of wheel carrier.

Note!
^ Observe torque on residual pressure restraint valve.





1. Fit pressure pipe on -residual pressure restraint valve (arrow)-. Tightening torque: 3 Nm (2 ft. lbs.).





2. Fit ball joint of tie rod on wheel carrier. Tighten -fastening nut- to prescribed tightening torque.
3. Fit wheel. Operate the brake whilst doing so (2 workers required).
4. Fit cowl panel cover and respective side engine compartment lining.
5. Fit windscreen wiper arms.
6. To fill the level control system, use the Porsche System Tester. To do this, select the Fill level control menu item in the Level control system. Switch on level control.