489819 Removing and installing hydraulic pump (PDCC)
WM 489819 Removing and installing hydraulic pump (PDCC)
General
Position of hydraulic pump on engine
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 servo pump as a result of 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 defective part on the pressure side should be replaced.
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.
-> Run the engine for about 20 seconds prior to the fluid level check. 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.
Preliminary work
Hydraulic pump V8 PDCC
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.
1. Remove left front wheel. => 440519 Removing and installing wheel - section on "Removing"
2. Remove engine guard. => 108019 Removing and installing engine guard - section on "Removing"
3. Remove front left wheel housing liner. Once the air cleaner housing is removed -arrow- , the engine compartment can be accessed easily => 505619 Removing and installing front wheel housing liner - section on "Removing".
4. Remove the left engine compartment cover. => 700219 Removing and installing front trim (engine compartment) - section on "Removing"
Removing hydraulic pump (Cayenne Turbo/Cayenne S)
Information
- The engine does not need to be removed to remove and install the hydraulic pump.
Hydraulic pump V8 PDCC
1. Pull the cover of the throttle body up and off -arrow-.
Cover 4.8 V8
2. Remove air box for throttle housing (Y-pipe). => 243519 Removing and installing air box for throttle housing (Y-pipe) - section on "Removing"
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.
3. Remove the left air cleaner housing => 242519 Removing and installing air cleaner housing - section on "Removing". To do this, follow Steps 4 and 5 -air path on Cayenne Turbo (left side)-. Steps 5 to 11 are not relevant for the Cayenne S.
4. Disconnect intake manifold at the air cleaner cover. Remove the air cleaner cover on the Cayenne S.
5. To do this, turn the -pins 180°- and pull them out. Then pull off the intake manifolds.
6. Once the lid is removed, remove the intake manifold completely along with the clamp. To do so, disconnect the positive crankcase ventilation pipe at the pressure pipe -arrow- and at the hydraulic pump -arrow- (clamp locks).
7. Separate the pressure pipe at the turbocharger and at the charge air cooler from below (engine guard removed).
8. Loosen the pulley on the hydraulic pump. Do so by slackening the drive belt -see figure- and set it aside. => 137801 Checking drive belt - section on "Checking"
9. Remove pulley on hydraulic pump completely.
10. Loosen the hydraulic lines at the pump slightly, but do not remove them.
11. Remove the hydraulic pump (front Torx E12) and let it hang.
Information
The line -2- can only be removed/fitted if the hydraulic pump is raised slightly (approx. 3mm).
Hydraulic pump connections
12. Remove the line connections -1 and 3-. Only loosen the line connection -2-. Close the open connections using suitable and clean (.) plugs. Collect emerging hydraulic fluid in a suitable container. Raise the hydraulic pump slightly, pull the line -2- carefully down and out, and then seal it.
13. Remove the hydraulic pump.
Installing hydraulic pump (Cayenne Turbo/Cayenne S)
Information
- Only use Pentosin CHF 202 to fill the hydraulic system.
- Pay attention to the hydraulic fluid level.
- Replace sealing rings.
- Use correct tightening torques => 4300TW Tightening torques
- Use correct tightening torques => 48 Tightening torques for steering.
Information
The line -2- can only be removed/fitted if the hydraulic pump is raised slightly (approx. 3mm).
Hydraulic pump connections
1. Insert the hydraulic pump and position the lower line -2- (do not fit).
2. Fit the hydraulic pump.
3. Fit pulley on the hydraulic pump and screw in the screws.
4. Fit drive belt in correct position and tension as required. => 137801 Checking drive belt - section on "Checking"
5. Tighten the pulley on the hydraulic pump.
Information
The M6 thread of the fastening screw for the pressure lines at the hydraulic pump -3- must be cleaned by blowing them out with compressed air before assembly.
Hydraulic pump connections
6. Fit the hydraulic lines.
7. Fit the pressure pipe on the turbocharger and on the charge air cooler. Connect positive crankcase ventilation pipe at the pressure pipe and at the hydraulic pump (not Cayenne S). Position heat shield.
8. Fit intake manifold on the turbocharger (not Cayenne S) and install air cleaner housing. => 242519 Removing and installing air cleaner housing - section on "Installing"
9. Fit air box for throttle housing (Y-pipe). => 243519 Removing and installing air box for throttle housing (Y-pipe) - section on "Installing"
10. Fit the air cleaner element and the cover for the air cleaner housing.
11. Fit intake manifold on cover for air cleaner housing.
12. Insert wheel housing liner. => 505619 Removing and installing front wheel housing liner - section on "Installing"
Subsequent work
Information
- The hydraulic system (steering) must be bled following repairs => 48 Test and assembly work on power steering. Vehicle must be lowered onto the wheels for this.
- Only use Pentosin CHF 202 to fill the hydraulic systems.
- Note hydraulic fluid levels.
- Both hydraulic fluid containers must always be filled (PDCC and steering). The containers must not run dry.
1. Fit the wheel and tighten to the prescribed tightening torque. => 440519 Removing and installing wheel - section on "Installing"
2. Fit the engine guard. => 108019 Removing and installing engine guard - section on "Installing"
3. Fill the two hydraulic fluid containers (PDCC and steering). The fluid level of the two containers must be checked continually during the following operations.
4. Top up and check the fluid level (PDCC). => 430501 Checking fluid level (PDCC)
5. Bleed the hydraulic system (steering) 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 Test and assembly work on power steering
6. Allow the engine to run while stationary for approx. 10 minutes (scavenging the PDCC system). Then connect the PIWIS Tester.
7. Select the Cayenne PDCC menu item and work through the following points in sequence. Follow the instructions on the PIWIS Tester:
- Drive links >> Valve timing.
- Drive links >> Bleed. => 430307 Bleeding Porsche Dynamic Chassis Control (PDCC)
- Drive links >> Perform system test.
- Read out and erase fault memory.
- Perform a test drive.
- Read out the fault memory again.