Removing and Installing Front Spring Strut (Air Springs)
Removing and installing front spring strut (air springs)Tools
Preliminary work
1. Remove cowl panel.
2. Remove the relevant engine compartment side cover.
3. Remove hub cap using puller hook 9229 and undo drive shaft fastening at the side of the wheel before raising the vehicle.
Operate the brake whilst doing so (second fitter required).
4. Remove wheel.
Removing front spring strut
The air springs are installed as standard in the Cayenne Turbo and are optional in the Cayenne S. The steel springs are not applicable for the Cayenne Turbo.
ATTENTION:
Increased risk of accident due to raising the wheel carrier incorrectly.
^ Injury and material damage possible.
^ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When raising the suspension, 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. To bleed the level adjustment system (compressed air must be released from the system), use the Porsche System Tester. To do this, select the Bleed level adjustment menu item in the Level adjustment system.
2. Lift wheel carrier carefully to facilitate removal. Use a suitable - lift with rubber base in order to prevent slipping.
3. Loosen pressure line at the residual pressure retaining valve -arrow- using insert part T10212.
4. Separate compact connector (in wheel housing on side member) -arrow- and the plug connections for the wheel acceleration sensor and self-levelling sensor.
5. Remove lower connecting link -arrow- using the lift to support the wheel carrier (assembly aid).
6. Unscrew plastic nuts -arrows- on wheel housing liner.
7. Fix upper trailing arm using spring compressor VW 552. This involves tensioning the trailing arm slightly because otherwise the top ball joint can be damaged. Insert the -figure- spring compressor into the top opening of the wheel housing (double panel under the wheel housing cover) and attach it to the trailing arm. This is only necessary if the same control arm is reinstalled.
8. Remove lower spring strut and undo brake caliper.
9. Slide protective tube (shop made) 00000 over drive shaft. Release drive shaft at transmission flange and lay down carefully. Use a suitable base for the front axle carrier.
10. Using universal drive shaft/wheel hub puller as of model 86 NR.87-1, push (press through) peg of drive shaft by approximately 20 mm - 25 mm into the wheel hub.
11. Remove the two holders (brake hose, combination line) on wheel carrier and let them hang.
12. Disconnect ABS sensor plug connection.
13. Remove the relevant outer -figure- tie rod joint using the press-out tool T10187. When pressing out, screw fastening nut on flush (this protects the ball joint thread).
14. Press out - ball joint of upper trailing arm from wheel carrier using press-out tool T10187.
15. Remove the spring compressor VW 552.
16. Remove brake caliper fastening screws and hang -figure- brake caliper in a suitable place in the wheel housing.
17. Remove drive shaft. To do this, the first fitter must carefully pull the top of the wheel carrier outwards and the second fitter must carefully guide out the drive shaft.
18. Remove the three mounts for the spring strut in the engine compartment (two mounting points in front of plenum panel and one inside the plenum panel). The three mounting points -(arrow)- are shown here from inside the wheel housing (wheel carrier installed).
19. Carefully guide out the spring strut.
Installing front spring strut
ATTENTION:
Increased risk of accident due to raising the wheel carrier incorrectly. When filling the air spring struts, the vehicle lifts.
^ Injury and material damage possible.
^ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When raising the suspension, use a suitable intermediate layer (hard rubber).
^ Do not damage the brake cover plate.
Note;
^ Visually inspect all parts.
^ If a new spring strut is fitted, it must be pre-filled 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 being 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.
^ Observe correct tightening torques.
1. Carefully guide in spring strut -arrow-, position with the auxiliary pins and tighten at the mounting saddle with the specified tightening torque.
2. Fit drive shaft. To do this, first fitter must carefully pull the top of the wheel carrier outwards and the second fitter must carefully guide in the drive shaft.
3. Fit brake caliper on wheel carrier (do not tighten brake caliper fastening screws yet).
4. Mount wheel carrier on upper trailing arm. When doing this, observe drive shaft clearance (use suitable base). To facilitate assembly and avoid the upper ball pin falling into the stop, raise the wheel carrier slightly with a suitable lift so that the upper ball pin can be inserted. Use a - lift with rubber base in order to prevent slipping.
5. Insert spring compressor VW 552 and slightly tension upper trailing arm.
6. Fit fastening bolt for lower spring strut. Remove spring compressor VW 552 tension jack.
7. Grease mounting-face ring of axle nut with a little Optimoly TA aluminum paste. Screw on axle nut to prevent the shaft from slipping out. If the shaft cannot be pushed right in, use assembly fixture T10206 to pull the drive shaft in. Remove protective tube (shop made) 00000 and base.
8. Fit drive shaft to the transmission flange and tighten brake caliper fastening screw.
9. Mount connecting link.
10. Connect compact connector in wheel housing -arrow-. Mount support for brake hose/combination line on top of wheel carrier. Connect sensor connectors.
Note: Observe torque on residual pressure retaining valve.
11. Fit pressure line at residual pressure retaining valve -(arrow)- using insert part T10212. Note tightening torque.
12. Mount ball joint of tie rod on wheel carrier. - Tighten lock nut to specified tightening torque.
13. Screw in plastic nuts -arrows- on wheel housing liner.
Subsequent work
1. Fit wheel.
2. Tighten axle nuts. Operate the brake whilst doing so (second fitter required).
3. Fit the relevant engine compartment side cover.
4. Fit cowl panel.
5. To fill the level adjustment system, use the Porsche System Tester. To do this, select the Fill level adjustment menu item in the Level adjustment system. Switch on level adjustment.