Power Steering Pump: Service and Repair
WM 489819 Removing and installing hydraulic pump (PDCC)
Preliminary work
Preliminary work for removing and installing hydraulic pump (PDCC)
1. Remove the left front wheel. -> 440519 Removing and installing wheel - section on "Removing" Removal and Replacement
2. Remove engine guard. -> 108019 Removing and installing engine guard - section on "Removing" 108019 Removing and installing engine guard
3. Remove front wheel housing liner at the left. -> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair
4. Remove the air box for the throttle housing (Y-shaped pipe). -> 243519 Removing and installing air box for throttle housing (Y-shaped pipe) - section on "Removing" 243519 Removing and installing cowl for throttle housing (Y-pipe)
5. Remove air cleaner housing at the left. -> 242519 Removing and installing air cleaner housing - section on "Removing" Service and Repair
Removing hydraulic pump (PDCC)
CAUTION
Increased risk of accidents and material damage if too much Pentosin CHF 202 is filled in or if Pentosin CHF 202 comes into contact with the coolant hoses when filling or topping up.
- It is possible to overfill the system, causing Pentosin CHF 202 to overflow onto coolant hoses and other components.
-> Before checking the fluid level, run the engine for approx. 20 seconds. Multiple steering operations (manoeuvring) will change the fluid level in the reservoir. Check the fluid level.
-> If coolant hoses come into contact with Pentosin, clean them thoroughly with water IMMEDIATELY.
-> Replace visibly swollen coolant hoses.
Information
- The rack-and-pinion steering gear and power-steering pump must not be repaired or dismantled!
- Always replace the O-rings on hydraulic lines!
- Ensure absolute cleanliness at all times!
- The reservoir must always be replaced if individual or multiple components, such as the tandem pump, PDCC valve blocks (FA/RA), PDCC anti-roll bars (FA/RA) are replaced.
- If system faults still occur after replacing a component (another component is defective), the reservoir does not have to be replaced again.
- Steel flexi-pipes must not be kinked or crushed.
- Observe safety requirements! -> 4303AW Safety requirements for Porsche Dynamic Chassis Control (PDCC) Service Precautions
Information
- Damage to the power steering will occur if there is a shortage of oil in the hydraulic system. Even small leaks can cause the hydraulic fluid to escape and damage the power-steering pump as a result of high oil pressure 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 defective part on the pressure side should be replaced.
Information
- The engine does not need to be removed to remove and install the hydraulic pump.
Information
- Cayenne Turbo only: Before removing the cover of the air cleaner box, the intake manifold of the turbocharger must be disengaged from the air cleaner housing.
- Loosen the pulley of the hydraulic pump before removing the drive belt.
Information
- The pictures shown in this document may differ from the original.
- However, this does not affect the validity and relevance of the pictures.
Installation position of hydraulic pump
1. Turbo only:
Remove intake manifold from the air cleaner housing to the turbocharger.
Remove the air cleaner cover on the Cayenne S.
2. To do this, turn the pins -arrows- and pull them out. Then pull off the intake manifold.
Removing intake manifold from air cleaner to turbocharger (shown as an example)
3. Turbo only:
Loosen the clamp -2- and pull the check valve -1- out of the air box.
Check valve for positive crankcase ventilation
4. Turbo only:
Remove clamps -1, 2- on the check valve.
Removing clamps
5. Turbo only:
Pull off hoses at the check valve. -arrows-.
6. Turbo only:
Disconnect and pull off wastegate line at the clamp -1-.
Wastegate line
7. Remove clamp -1- from the lift switchover hose -2- and pull off the hose -A-.
Lift switchover clamp
8. Remove hose clamp -1- on the turbocharger -2- and pull off the hose -3- ( -A- ).
Turbo hose clamp
9. Loosen the fastening screws -1- on the pulley for the hydraulic pump -2- ( -3- ).
Hydraulic pump pulley
10. Relieve and remove the drive belt.
To do this, use an open-ended wrench (a/f 30) to turn the belt tensioner clockwise -arrow- and remove the drive belt from the tensioning roller -8-. Then relieve the belt tensioner slowly.
Removing drive belt
11. Remove the hydraulic pump pulley completely => Hydraulic pump pulley.
12. Remove the two intake pipes -1, 2- at the cylinder head -4-.
Mounting for intake pipes
12.1. To do this, loosen the fastening nut -3- on the holder.
13. Pull the intake pipes -1, 2- out of the hydraulic pump -3- ( -arrows- ).
Removing hydraulic lines
13.1. Loosen the fastening nut -4- on the holder at the hydraulic pump -3-.
13.2. Lever out the two lines -1, 2- using a suitable tool -5- and remove them from the hydraulic pump -3-.
13.3. Close off the open connections for the lines and the hydraulic pump using suitable stoppers.
13.4. Collect emerging hydraulic fluid in a suitable container.
14. Disconnect the pressure lines from the hydraulic pump.
Disconnecting pressure lines
14.1. Loosen the screw -1- on the lower pressure line and pull the line out of the hydraulic pump -A-.
14.2. Loosen the banjo bolt -3- on the pressure supply tank -4- and pull it out -B-.
15. Unscrew the three fastening screws -2- at the front of the hydraulic pump.
16. Unscrew the fastening screw -3- at the side of the hydraulic pump.
Fastening screws on hydraulic pump (shown as an example)
17. Take the hydraulic pump out of the vehicle.
Installing hydraulic pump (PDCC)
Information
- In vehicles without Servotronic, the hydraulic system must be flushed with approx. two litres of Pentosin.
- The reservoir must always be replaced if individual or multiple components, such as the hydraulic pump (tandem hydraulic pump), steering, PDCC valve blocks (FA/RA), PDCC anti-roll bars (FA/RA), are replaced.
- The hydraulic system must be bled after repair work is carried out. The vehicle must be lowered onto the wheels for this. -> 4890IN Test and assembly work on power steering Testing and Inspection
- Only use Pentosin CHF 202 to fill the hydraulic system.
- Check the hydraulic fluid level.
- Replace sealing rings.
- Observe correct tightening torques. -> 4X00IN Tightening torques for steering [1][2]Specifications
Information
- Make sure not to damage the radiator grilles.
1. Carefully fit the hydraulic pump from the side.
2. Carefully fit the three fastening screws -2- at the front and the fastening screw -3- at the side of the hydraulic pump and then tighten all screws to the specified tightening torque.
Fastening screws on hydraulic pump (shown as an example)
3. Replace the sealing ring -1- on the lower pressure line -2-.
Sealing ring on pressure line
4. Fit the pressure lines to the hydraulic pump.
Fitting pressure lines
4.1. Insert the lower pressure line -1- into the hydraulic pump -2- and fit it -A-.
4.2. Fit the upper pressure line to the pressure supply tank -4- ( -arrow- ) and secure with the banjo bolt -3-.
Use new sealing washers -5-.
5. Replace sealing rings -1, 2- on the intake pipes -3, 4-.
Sealing rings on intake pipes
6. Insert the intake pipes -1, 2- into the hydraulic pump -3- ( -arrows- ), position the holder -4- and screw on the fastening nut -5-.
Fitting intake pipes
7. Fit the intake pipes -1, 2- at the cylinder head -4- using the holder and screw on the fastening nut -3-.
Mounting for intake pipes
8. Fit the pulley -2- on the hydraulic pump -3- and screw in the fastening screws -1-.
Hydraulic pump pulley
9. Fit the drive belt at the correct position and tension it. -> 137819 Removing and installing drive belt - section on "Installing" Service and Repair
10. Fit the fastening screws -1- on the pulley -2- for the hydraulic pump -3-.
11. Fit the intake manifold on the turbocharger.
12. Turbo only:
Connect the wastegate line at the clamp -1-.
Wastegate line
13. Turbo only:
Attach the check valve -1- to the air box and fit the clamp -2-.
Check valve for positive crankcase ventilation
14. Turbo only:
Attach hoses to the check valve and fit with new clamps.
15. Fit the lift switchover hose to the intake manifold.
Subsequent work
Subsequent work for removing and installing hydraulic pump (PDCC)
Information
Pentosin in engine compartment
- The reservoir is located at the front left of the engine compartment.
- A dipstick with MAX/MIN markings is mounted on the cap of the reservoir. They are for a fluid level with a cold engine (approx. 20°C).
- The MAX marking can be easily exceeded at higher temperatures.
- Check the fluid level (Pentosin CHF 11 S) when the engine is not running and when it is cold (approx. 20°C).
1. Install air cleaner housing. -> 242519 Removing and installing air cleaner housing - section on "Installing" Service and Repair
2. Fit the air box for the throttle housing (Y-shaped pipe). -> 243519 Removing and installing air box for throttle housing (Y-shaped pipe) - section on "Installing" 243519 Removing and installing cowl for throttle housing (Y-pipe)
3. Fit wheel housing liner. -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair
4. Fit engine guard. -> 108019 Removing and installing engine guard - section on "Installing" 108019 Removing and installing engine guard
5. Fit the left front wheel. -> 440519 Removing and installing wheel - section on "Installing" Removal and Replacement
6. Fill the reservoir and do not exceed the MAX marking.
7. Bleed the PDCC and hydraulic power-steering system. -> 430307 Bleeding Porsche Dynamic Chassis Control (PDCC) 430307 Bleeding Porsche Dynamic Chassis Control (PDCC)