Power Steering - Component Replacement
Cayenne5/03 4898
Binder - 4 - Running Gear
Power Steering System Hydraulic Pump
Date: 10-24-03
Vehicle Type:
Cayenne S / Cayenne Turbo
Model Year:
As from '03 (3)
Concerns:
Additional parts required when removing and installing the power steering system hydraulic pump.
Information:
When replacing the hydraulic pump, other parts which are not listed in the Technical Manual have to be replaced as well. The number and type of parts required depends on whether the vehicle is filled with power steering (I no. 1N1) or Servotronic (I no. 1N3).
Caution!
Risk of damage from contact of "Pentosin CHF 11 S" with the coolant hoses.
> If the coolant hoses come into contact with Pentosin, thoroughly clean them with water immediately.
> Replace any coolant hoses which are visibly swollen.
Work Procedure:
Different parts are required for vehicles with power steering or Servotronic. Basically, with all vehicles, the hydraulic system must be flushed out with 2 liters Pentosin after replacing the hydraulic pump. For the flushing procedure, refer to the Technical Manual, Group 4, 4898 - Removing and installing hydraulic pump.
Vehicles With Power Steering (I no. 1N1)
1. For vehicles with power steering, check which hydraulic fluid reservoir has been filled to the vehicle. Vehicles are filled with hydraulic fluid reservoir, Part Number, 955 314 015 00 when leaving the factory. This must be replaced with reservoir, Part Number, 955 314 015 10.
Reason: The reservoir with, Part Number, 955 314 015 10 has been filled with a finer filter. Residual particles of dirt which may still be present in the hydraulic system after flushing it out will be trapped by this filter.
Distinguishing characteristic of the hydraulic fluid reservoir:
The reservoirs can be distinguished by the number which is located on the top (Figure 1) and interpreted in terms of their part number:
2. On vehicles which were manufactured before March 10, 2003 and up to the following VINs:
9P8 4LA 90071 Cayenne Turbo / USA
9P4 3LA 60258 Cayenne S / USA
the hose, Part Number, 955 347 442 00, leading from the hydraulic pump to the hydraulic fluid reservoir must also be replaced.
Vehicles With Servotronic (I no. 1N3):
On vehicles which were manufactured before March 10, 2003 and up to the following VINs:
9P8 4LA 90071 Cayenne Turbo / USA
9P4 3LA 60258 Cayenne S / USA
the hose, Part Number, 955 347 442 00, leading from the hydraulic pump to the hydraulic fluid reservoir must also be replaced.
Parts Information:
Literature:
Cayenne Technical Manual, Group 4:
> Repairs: 48-10 - Removing and installing hydraulic pump
(refer also to the attachment; the chapter is being published with Supplement 19)
Attachment:
Repairs: 48-10 - Removing and installing hydraulic pump
Removing and installing hydraulic pump (Cayenne Turbo/Cayenne S)
Position of hydraulic pump on engine
General
Damage to the power steering is caused by a shortage of oil in the hydraulic system. Even small leaks can cause the hydraulic fluid to escape and damage the servo pump as a result of the high oil pressure occurring in the hydraulic circuit.
"Grunt-like" noises that can be heard when the steering is locked, or foam formation in the reservoir indicate a shortage of oil and/or that air has also been sucked in. Before filling the reservoir, any existing leaks must be eliminated on the suction side. Alternatively, the detective part on the pressure side should be replaced.
Caution!
Danger of damage to property if too much Pentosin CHF 11 S is filled or if Pentosin CHF 11 S comes into contact with the coolant hoses when tilling or topping up.
^ Observe the following specifications in order to avoid overfilling and thus overflowing.
^ The engine must he run tar approx. 20 seconds prior to the fluid level check. Multiple steering operations (maneuvering) change the fluid level in the reservoir.
Check fluid level
^ If coolant hoses come into contact with Pentosin, thoroughly clean them with water IMMEDIATELY.
^ Replace visibly "swollen" coolant hoses.
Removal
Note!
The engine does not have to be removed in order to remove and install the hydraulic pump.
Hydraulic pump (belt pulley removed)
1. Remove left front wheel --> 44-5 "Removing and installing wheel".
2. Remove engine guard --> Rep. Gr. 108019; Removing and installing engine guard.
3. Remove front left wheel housing liner. The engine compartment can be accessed once the -air cleaner housing (arrow)- is removed --> 6; Rep. Gr. 505619; Removing and installing wheel housing liner.
4. Remove left engine compartment cover --> 70; Rep. Gr. 70 02
19; Removing and installing front cover.
5. Pull the cover of the throttle body vertically upwards.
6. Remove cowl for throttle body (Y-shaped pipe) --> 2; Rep. Gr. 243519; Removing and installing Y-shaped pipe.
Note!
^ Cayenne Turbo only: Before removing the air cleaner compartment lid, the intake manifold of the turbocharger must be disengaged from the air cleaner housing.
^ Loosen the belt pulley of the hydraulic pump before removing the drive belt.
7. Remove the left air cleaner housing --> 2; Rep. Gr. 242519;
Removing and installing air cleaner housing. To do this, refer to points 8 and 9-air flow for Cayenne Turbo (left side)-.
Points 9 to 11 are not relevant for the Cayenne S.
8. Disconnect intake manifold on air cleaner lid. Remove the air cleaner cover on the Cayenne S.
9. To do this, turn the pins 1800 and pull them out. Then pull off the Intake manifolds.
10. Once the lid is removed remove the intake manifold completely along with the clamp. To do so, disconnect crankcase venting pipe at the pressure pipe -arrow- and up to the hydraulic pump -arrow- (clamp locks).
11. Separate the pressure pipe on the turbocharger and on the charge air cooler from below (engine guard removed).
12. Loosen drive belt on hydraulic pump. To do this, -relieve tension on drive belt- and set it aside 1; Rep. Gr. 137801; Removing and installing drive belt.
13. Remove belt pulley on hydraulic pump completely.
14. Clamp both lines to the hydraulic pump (suction line, pressure pipe) as close as possible to the hydraulic pump using a 3094 hose clamp.
15. Remove both lines to the hydraulic pump (suction line, pressure pipe). Close the open connections with suitable plugs. Collect emerging hydraulic fluid in a suitable container.
16. Remove the hydraulic pump (3 x front Torx E12, 1 x rear Torx E12).
Installation
Note!
^ In vehicles without Servotronic, the hydraulic system must be rinsed with approx. two litres of Fentosin.
^ The hydraulic system must be bled following repair work 48-2 Test and assembly work on power steering". Vehicle must be lowered onto the wheels for this.
^ Only use Pentosin CHF 11 S to fill the hydraulic system.
^ Pay attention to the hydraulic fluid level.
^ Replace sealing rings.
^ Observe the information in the Technical Information Replacing servo pump: Group 4 No. 5/03 when replacing the hydraulic pump.
^ Use correct tightening torques "Tightening torques for steering".
1. Fit the hydraulic pump (tightening torque: 23 Nm (17 ftlb.).
2. Fit belt pulley of the hydraulic pump and insert screws.
3. Install drive belt in correct position and tighten --> 1;
Rep. Sr. 137801; Removing and installing drive belt.
4. Tighten belt pulley on hydraulic pump to 23 Nm (17 ftlb.).
5. Fit both hydraulic lines (tightening torque: banjo bolt 30 (22 ftlb.) + 3 Nm (2 ftlb.), M6 screws 10 Nm (7.5 ftlb)). Remove 3094 hose clamps.
6. Fit the pressure pipe on the turbocharger and on the charge air cooler. Connect crankcase venting pipe at the pressure pipe and up to the hydraulic pump (not Cayenne S). Position heat shield.
7. Fit intake manifold on the turbocharger (not Cayenne S) and install air cleaner housing --> 2; Rep. Sr. 242519; Removing and installing air cleaner housing.
8. Fit cowl for throttle body (Y-shaped pipe) --> 2; Rep. Sr. 243519; Removing and installing Y-shaped pipe.
9. Fit the air cleaner element and the lid for the air cleaner housing.
10. Fit intake manifold on air cleaner housing lid.
11. Install wheel housing liner --> 6; Rep. Sr. 505619; Removing and installing front wheel housing liner.
12. Disconnect pressure pipe on the servo oil cooler (line leading to the hydraulic fluid tank). Have a suitable plug ready for closing the line (hydraulic fluid escapes!). Collect emerging hydraulic fluid in a suitable container.
13. Fill the hydraulic fluid tank. Use a suitable auxiliary hose (approx. 10 - 15 cm, shop-made) to carry hydraulic fluid that emerges during rinsing into a suitable container (approx. 1.5 litres).
14. Rinse the hydraulic system with the engine running by turning the steering several times to the right or left stop, and adjust the hydraulic fluid level several times as required. Vehicle must be lowered onto the wheels for this. The tank must not run on empty while the engine is running (two workers required).
15. Fit the pressure pipe on the servo oil cooler.
16. Bleed the hydraulic system with the engine running by turning the steering several times to the right or left stop, and adjust the hydraulic fluid level several times as required --> 48-2 "Test and assembly work on power steering".
17. Fit the wheel and tighten to the prescribed tightening torque --> 44-5 "Removing and installing wheel".
18. Install engine guard Rep. Sr. 108019; Removing and installing engine guard.
Disclaimer