407719 Removing and installing front anti-roll bar (PDCC)
WM 407719 Removing and installing front anti-roll bar (PDCC)
Preliminary work
1. Raise the vehicle at the jacking points provided for this purpose. -> 4X00IN Lifting the vehicle Service and Repair
2. Remove engine guard. -> 108019 Removing and installing engine guard - section on "Removing" 108019 Removing and installing engine guard
Information
Component information
Installation position of front anti-roll bar (PDCC)
Removing front anti-roll bar (PDCC)
WARNING
Caustic fluids
- Danger of chemical burns
-> Avoid contact with caustic fluid.
-> Wear personal protective gear.
-> Ensure that there is good ventilation.
-> If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
Information
PDCC chassis:
- Steel flexi-pipes are particularly sensitive to kinking and crushing.
- Treat the steel flexi-pipes with great care when removing, storing and reinstalling the anti-roll bar.
- Make sure that the steel flexi-pipes are not subject to any mechanical loads during the following operations.
- When removing, mark the installation position of the lines using a touch-up stick.
- When installing, make sure that the clamp is seated correctly.
- The steel flexi-pipes must not be twisted when installed under any circumstances.
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. Only for 19-inch or larger brake systems: Unscrew the fastening screws on the air guide -8- at the left and right. Use a suitable tool to counter the fastening nuts -9-.
Air guide
2. Mark the installation position -arrow- of the anti-roll-bar mount halves with respect to the anti-roll bar with a paint marker.
Marking on anti-roll bar halves (shown as an example)
3. Mark the two lines using a touch-up stick, from the steel flexi-pipe to the anti-roll bar housing -arrows-.
Marking (shown as an example)
4. Loosen the expansion hose at the two fastening points -arrows- and unclip it carefully at the sides.
Fastening points for PDCC expansion hose (shown as an example)
Information
The anti-roll bar halves can turn following removal and hydraulic fluid will leak out.
- Close the openings in the anti-roll bar using suitable plugs or screw plugs.
5. Remove the two lines at the anti-roll bar. Use a container to collect emerging fluid and close the lines using suitable stoppers.
6. Remove connecting link at the left and right of the anti-roll bar.
7. Remove the four fastening screws on the anti-roll bar and take off the clamps.
8. Open and remove the two hose clamps.
9. Carefully remove the anti-roll bar while taking care not to damage adjacent components.
Installing front anti-roll bar (PDCC)
WARNING
Caustic fluids
- Danger of chemical burns
-> Avoid contact with caustic fluid.
-> Wear personal protective gear.
-> Ensure that there is good ventilation.
-> If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
1. Mount the anti-roll bar halves at the correct position on the anti-roll bar. At the correct position means the larger outer diameter is on the wheel side.
Anti-roll bar halves (shown as an example)
2. Engage the anti-roll-bar mount halves at the mounting points provided for this purpose -arrow-.
Mounting points (shown as an example)
3. Check the installation position -arrow- of the anti-roll-bar mount halves with respect to the anti-roll bar. Copy the dimensions of the marking -arrow- on the old roll-over bar when installing a new roll-over bar.
Marking on anti-roll bar halves (shown as an example)
Information
- All screws and bolts on the axle must be tightened in vehicle position. Vehicle position means: vehicle resting on its wheels, or the wheel suspension is lifted with a universal jack. -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 front axle 4X00IN Tightening torques for front axle
4. Fit the anti-roll bar and insert the four fastening screws evenly in vehicle position and tighten hand-tight.
5. Fit the two hose clamps.
6. Fit the fastening screws for the anti-roll bar at the connecting links and tighten hand-tight.
7. Fit the two steel flexi-pipes. The markings must be aligned precisely during installation -arrows-.
Marking (rear anti-roll bar shown)
8. Tighten the fastening screws for the anti-roll bar and connecting links to the specified tightening torques -> 4X00IN Tightening torques for front axle 4X00IN Tightening torques for front axle.
9. Only for 19-inch or larger brake systems: Tighten the fastening screws on the air guide -8- at the left and right. Use a suitable tool to counter the fastening nuts -9-.
Air guide
10. Following assembly, check carefully once again that the steel flexi-pipes are not twisted! The toothed rings -arrows- must be positioned on the steel flexi-pipes in such a way that they provide adequate protection in the event of contact with adjacent components.
Position of toothed rings (shown as an example)
Subsequent work
1. Install engine guard. -> 108019 Removing and installing engine guard - section on "Installing" 108019 Removing and installing engine guard
2. Lower the vehicle. -> 4X00IN Lifting the vehicle Service and Repair
3. Bleed the PDCC system. -> 430307 Bleeding Porsche Dynamic Chassis Control (PDCC) 430307 Bleeding Porsche Dynamic Chassis Control (PDCC)