432519 Removing and installing rear spring strut (air springs)
WM 432519 Removing and installing rear spring strut (air springs)
Tools
Preliminary work
Preliminary work for removing and installing rear spring strut (air springs)
1. Remove the relevant side panel of the luggage compartment cover. -> 700619 Removing and installing luggage compartment trim panel (luggage compartment cover) - section on "Removing"
2. Remove the wheel -> 440519 Removing and installing wheel - section on "Removing" Removal and Replacement.
3. Bleed the spring strut.
To bleed the levelling system (compressed air must be released from the system), use the Porsche System Tester. To do this, select the Bleed levelling system menu item in the Levelling system. -> 4301IN Bleeding and filling levelling system 4301IN Bleeding and filling the levelling system
Removing rear spring strut (air springs)
WARNING
Working with compressed air
- Risk of eye injuries
- Risk of damaging and dirtying components
-> Wear protective goggles with side eye protection.
-> Protect the point at which the compressed air emerges with suitable material.
-> Place the point at which the compressed air emerges on suitable surfaces.
Information
- Spring strut screws are under tension. Use a suitable lift with rubber base.
- Do not damage the brake cover plate.
Raising rear wheel bearing housing (shown as an example)
Information
Raise the wheel suspension slightly using a transmission jack (do not raise wheel suspension higher than normal vehicle position (vehicle resting on its wheels). This changes the angular position of the control arm and the spring strut can be removed by turning carefully.
Rear spring strut (air springs)
1. Remove caps from the top screws on the spring strut at the front using a suitable tool.
Removing caps
2. Loosen fastening screws -1- on the upper spring strut, but do not remove them.
Upper spring-strut mount
3. Raise the vehicle.
4. Loosen the pressure line -1- at the pressure control valve -2- using insert tool T10212. Then move the pressure line aside and close it off using a suitable stopper.
Air can escape while doing this.
Pressure line for rear spring strut
5. Release electric plug connection -1- from the spring-strut wire harness -2- ( -a- ) and pull it off -A-.
Plug connection for rear spring strut (air)
6. Secure the spring strut using a suitable jack => Raising rear wheel bearing housing (shown as an example).
Raising rear wheel bearing housing (shown as an example)
7. Remove the lower spring strut -1- from the wheel bearing housing -2- and connecting link -4-. To do this, loosen the fastening screw -3-.
Spring strut screw (air springs)
8. Remove the jack and carefully lever the spring strut -1- out of the wheel bearing housing -2- using a suitable tool, e.g. mounting lever.
9. Lower vehicle.
10. A second mechanic is needed to hold and remove the spring strut.
The first mechanic unscrews the top fastening screws -1- on the spring strut completely.
The second mechanic holds the spring strut securely and then pulls it out of the vehicle.
Upper spring-strut mount
Installing rear spring strut (air springs)
WARNING
Unsecured climbing aid
- Danger of climbing aid falling over
- Danger of persons falling down
-> Secure the climbing aid to prevent it from slipping and tipping over.
WARNING
Wheel bearing housing raised incorrectly
- Risk of squashing
- Risk of damage to components
-> Wear personal protective gear.
-> Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
Information
- All screws and bolts on the axle must be tightened in vehicle position. Vehicle position means: vehicle standing on its wheels, or the wheel suspension is raised with a universal vehicle lift. Dimension -X- , from lower edge of wing to centre of axle corresponds to vehicle position. For the current height values, please refer to the adjustment values for suspension alignment -> 4495TW Adjustment values for suspension alignment 4495TW Adjustment values for suspension alignment.
Dimension X - lower edge of wing to centre of axle (shown as an example)
- Visually inspect all parts.
- Replace self-locking nuts.
- Replace all expansion screws (screws fitted using torque angle tightening procedure).
- Use correct tightening torques and torque angle. -> 4X00IN Tightening torques for rear axle 4X00IN Tightening torques for rear axle
Information
- When working on the air-spring strut, make sure that the air-spring strut does not become twisted.
- The air-spring struts are pre-filled to approx. 2.5 bar overpressure ex-works. If a new air-spring strut is installed, air can diffuse (escape) from the bellows of the air-spring strut as a result of storage times of varying duration. If the air-spring strut is removed from the transport packaging and installed without being filled, the bellows can fall into folds, thereby damaging the air-spring strut. For this reason, all air-spring struts must be re-filled prior to use. The procedure is described in detail in the course of the repair instructions. -> 4301IN Filling specification for air-spring strut Procedures
Information
- Do not remove air-spring strut from transport packaging until it has been filled. This will prevent damage to the inner bellows.
- During assembly work, make sure that there are no pressure marks on the protective boot of the air-spring strut.
Information
- The air-spring strut must only be filled with the approved gasses, nitrogen or oil-free compressed air.
- In some cases, up to 11 bar overpressure (upper tolerance, spring strut depressurised) is required to open the pressure control valve.
- Fill the air-spring strut using 3 to 4 shots of pressure. Filling the air with individual pressure shots will prevent the air-spring strut from being filled with too much overpressure.
- Do not fill the air-spring strut with overpressure of more than 2.5 bar.
Information
- Check the torque at the pressure control valve. -> 4X00IN Tightening torques for levelling system [1][2]Specifications
Information
- The pictures shown in this document may differ from the original.
- However, this does not affect the validity and relevance of the pictures.
1. A new air-spring strut must be filled before it is fitted. -> 4301IN Filling specification for air-spring strut Procedures
A second mechanic is needed for installing the spring strut.
2. Only raise the vehicle as far as required on the lifting platform so that a suitable jack can fit under the wheel bearing housing and a second mechanic can easily reach the luggage compartment floor with a small ladder. => Upper spring-strut mount
3. Carefully fit the spring strut -1- at the upper spring-strut mount.
4. When doing so, make sure that the pins -3- of the rocker bearing -2- fit exactly into the corresponding bore -4- on the body.
Upper spring-strut mount
5. Position the jack -2- as a support under the spring strut -1- and raise it as far as required -A- until the installation position of the spring strut no longer changes.
The rocker bearing must be flush with the body.
Installing spring strut
6. A second mechanic -3- must now climb onto a suitable pedestal -4- , or small ladder and fit and tighten the top screws -1- on the spring strut. Final tightening of the top fastening screws to the specified tightening torque is done in Step 11.
When fitting the screws, make sure that they do not tilt and can be screwed in easily.
Upper spring-strut mount
7. Raise the vehicle.
8. Insert the spring strut into the wheel bearing housing with the help of the jack.
Supporting the spring strut (shown as an example)
9. Fit the lower spring strut -1- with the wheel bearing housing -2- and connecting link -4-.
To do this, insert the fastening screw -3- through the components from behind and fit it.
Spring strut screw (air springs)
10. Plug in electric plug connection -1- for the spring strut -A- and lock it -a-.
Electric plug connection for rear spring strut (air springs)
11. Fit the pressure line -1- to the pressure control valve -2- using insert tool T10212 insert tool T10212, => Tightening torques. Then clip the pressure line into the retaining devices.
Pressure line for rear spring strut
12. Lower the vehicle.
13. Then fit the fastening screws -1- for the upper spring strut to the specified tightening torque.
The tightening sequence -A, B, C, D- must be strictly observed!
Installation sequence for upper spring strut screws
14. Secure the caps -1- on the top fastening screws for the spring strut at the front.
Fitting caps
Subsequent work
Subsequent work for removing and installing rear spring strut (air springs)
1. Fit the relevant side panel of the luggage compartment cover. -> 700619 Removing and installing luggage compartment trim panel (luggage compartment cover) - section on "Installing"
2. Mount wheel -> 440519 Removing and installing wheel - section on "Installing" Removal and Replacement.
3. To fill the air suspension (the system must be filled with compressed air), use the Porsche System Tester. -> 4301IN Filling specification for air-spring strut Procedures
4. Switch on the levelling system => Lifting the vehicle.