Removing front spring strut Porsche Cayenne S I

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.

Scheme 66

> 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. see scheme 82

3. Loosen pressure line at the residual pressure retaining valve -arrow- using insert part T10212. see scheme 83

Scheme 67

4. Separate compact connector (in wheel housing on side member) -arrow- and the plug connections for the wheel acceleration sensor and self-levelling sensor. see scheme 84

Scheme 68

5. Remove lower connecting link -arrow- using the lift to support the wheel carrier (assembly aid). (Scheme 65)

Scheme 69

6. Unscrew plastic nuts -arrows- on wheel housing liner. see scheme 86

Scheme 70

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 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. (Scheme 66)

Scheme 71

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.

Scheme 72

10. Using universal drive shaft/wheel hub puller as of model '86 NR.87-1 , push (press through) peg of drive shaft by approx. 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.

Scheme 73

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). see scheme 90

Scheme 74

14. Press out ball joint of upper trailing arm from wheel carrier using press-out tool T10187. (Scheme 67)

15. Remove the spring compressor VW 552 .

Scheme 75

16. Remove brake caliper fastening screws and hang brake caliper in a suitable place in the wheel housing. (Scheme 68)

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.

Scheme 76

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). (Scheme 69)

Scheme 77

19. Carefully guide out the spring strut.

Scheme 78

> 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 > Filling specification for air-spring strut. 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. (Scheme 72) Use an intermediate layer --> see figure (hard rubber). Do not damage the brake cover plate. (Scheme 73) 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. Refer to 40 TW Tightening torques for front axle - as of MY 2003 (All Models).

Scheme 79

1. Carefully guide in spring strut -arrow-, position with the auxiliary pins and tighten at the mounting saddle with the specified tightening torque Refer to 40 TW Tightening torques for front axle - as of MY 2003 (All Models). (Scheme 71)

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 --> see figure lift with rubber base in order to prevent slipping. (Scheme 73)

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.

Scheme 80

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 Refer to 40 TW Tightening torques for front axle - as of MY 2003 (All Models) .

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. (Scheme 78)

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. Refer to 40 TW Tightening torques for front axle - as of MY 2003 (All Models). (Scheme 79)

Scheme 81

12. Mount ball joint of tie rod on wheel carrier. Tighten lock nut to specified tightening torque Refer to 40 TW Tightening torques for front axle - as of MY 2003 (All Models). see scheme 104

13. Screw in plastic nuts -arrows- on wheel housing liner. see scheme 105

1. Fit wheel Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .

2. Tighten axle nuts Refer to 40 TW Tightening torques for front axle - as of MY 2003 (All Models) . Operate the brake whilst doing so (second fitter required).

3. Fit the relevant engine compartment side cover Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

4. Fit cowl panel Refer to 66 44 19 Removing and installing cowl panel cover - as of MY 2003 (All Models) .

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 Refer to 40 V0 Lifting the vehicle - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) . Refer to 40 V0 Lifting the vehicle - as of MY 2003 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) .

Note. These instructions for removal and installation describe all the sensors for the body (two sensors at the front, one sensor at the rear).

Installation position at front: Position 8, under the left and right wings.

Installation position at rear: Position 8, under the boot floor plate on the right (sensor can be accessed from the interior!).

Front sensor

1. Lift the vehicle. --> 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TURBO S, CAYENNE S TIO TITAN) or 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TIP, CAYENNE MAN, CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO) .

2. Remove wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner - as of MY 2003 (All Models) .

Rear sensor

Note. For removing and installing the rear sensor, it is not necessary to lift the vehicle. The rear sensor can be accessed from the interior.

1. Remove boot floor plate (center part) and remove only the right side cover. Refer to 70 06 19 Removing and installing luggage compartment trim (loadspace cover) - as of MY 2003 (All Models) .