Level Control: Other Porsche Cayenne I

Position of air suspension components

The Cayenne Turbo and the optional Cayenne and Cayenne S are equipped with a level adjustment system with full-supporting air suspension on both axles and the electronically regulated damping of Porsche Active Suspension Management (PASM).

The air suspension with level adjustment makes it possible to actively adapt the ground clearance of the Cayenne to the situation in which the vehicle is being used or to its load. More ground clearance off-road by manual adjustment to off-road level or automatic lowering at high speed.

Depending on the load, by increasing or decreasing the air volume it is possible to achieve various vehicle heights with different suspension characteristics. The amount of air needed for each air spring strut is determined by means of a control unit and provided via an air supply consisting of compressor, a solenoid block and two accumulators.

Wheel acceleration sensors -9- are no longer fitted as of January 2004. Precise data and scopes can be found in the spares catalogue. If the air-spring struts have to be replaced, the wheel acceleration sensors (for vehicles before January 2004) will need to be installed on the new air-spring struts. (Scheme 27)

Scheme 27

Adjusting car to normal level

Stop the vehicle and apply the brake.

Close vehicle doors.

Tap the right-hand rocker switch on the center console in the appropriate direction until vehicle has reached normal level. The middle indicator light next to the rocker switch is permanently on. If a further indicator light should come on, a different level is set.

Tools

Designation Type Number Explanation Compressed gas bottle with pressure gauge unit commercially available tool 00000 adapter VW-tool T10157/1

Scheme 28

Scheme 29

1- - Top part of air-spring strut with residual pressure retaining valve without plug connection (a/f 12). (The adapter T10157/1 is fitted to the residual pressure retaining valve before the air-spring strut is filled.)

2- - Compressed gas bottle with pressure gauge unit 00000 (The required pressure is set on the compressed gas bottle using the commercially available pressure gauge unit. The compressed gas bottle is filled with Argon or Corgon!)

3- - Air-spring filling unit VAS 6231 00000 (The air-spring strut can be filled with individual pressure shots using the air-spring filling unit.)

4- - Adapter T10157/1 (The adapter T10157/1 is fitted to the residual pressure retaining valve before the air-spring strut is filled.)

Filling the air-spring strut

> Observe the relevant operating regulations for handling compressed air and gas filling units.

> Observe accident prevention regulations.

Note. Do not remove air-spring strut from transport packaging until it has been filled. This will prevent damage to the inner bellows. The air-spring strut must be screwed securely in the transport packaging during filling. During assembly work, make sure that there are no pressure marks on the protective boot of the air-spring strut. After installation, first set the high level, then go to normal level. Repeat this procedure once more. This procedure replaces most of the gas with the cleaned air from the air supply unit.

1. Remove transport packaging lid.

2. Pull off protective cap on residual pressure retaining valve. Carefully remove any left-over packaging.

Scheme 30

3. Pull off plug connection on residual pressure retaining valve (a/f 12) and screw on the filling unit adapter T10157/1 at the correct position on the residual pressure retaining valve.

Scheme 31

Note. The air-spring strut must only be filled with the approved gasses, dual-process gasses Argon and Corgon. In isolated cases, up to 11 bar overpressure (upper tolerance, spring strut depressurised) is required to open the residual pressure retaining valve. Fill the air-spring strut using several individual pressure shots. 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 4.5 bar. The residual pressure retaining valve automatically reduces excessive overpressure to the minimum overpressure of approx. 3 bar.

4. Fit the filling unit to the pressure gauge unit of the compressed air bottle. (Scheme 30)

Scheme 32

5. Set the pressure gauge unit (flow limiter) to approx. 20 l/min -arrow-. (Scheme 31)

Scheme 33

6. Overcome the counter-pressure of the residual pressure retaining valve with several individual pressure shots and fill the air-spring strut. When sufficient air has been filled, between 2.5 and 4.5 bar -arrows-, pull off the connection from the residual pressure retaining valve. Do not exceed the maximum value of 4.5 bar. (Scheme 32)

7. Once the air-spring strut has been filled correctly, it can be removed from the transport packaging and fitted.

Removing front level sensor

Note. In running gear with level adjustment, a self-levelling sensor is installed on each spring strut. Removal and installation is described for the right spring strut. The self-levelling sensor is screwed to the bearing block and upper control arm.

Turn steering until access to the self-levelling sensor is achieved.

Scheme 34

1. Counter with an open-ended wrench on the two flats -1- and unscrew the fastening nuts -2-. (Scheme 33)

2. Unscrew both fastening screws -3-. (Scheme 33)

Scheme 35

3. Disengage lever from self-levelling sensor, swivel it forwards and remove the sensor.

4. Press the electric connector together -a- and pull it off. (Scheme 34)

Scheme 36

Note. In running gear with level adjustment, a self-levelling sensor is installed on each spring strut. Removal and installation is described for the right spring strut. The self-levelling sensor is screwed to the bearing block and upper control arm.

1. Press the electric connector onto the self-levelling sensor until it clicks into place.

Scheme 37

2. Tighten fastening screws -3- --> 43 TW Tightening torques - as of MY 2003 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne Turbo). (Scheme 36)

3. Engage lever of self-levelling sensor and position the sensor.

4. Position the fastening nut -2-, counter with an open-ended wrench on the two flats -1- and tighten the nut --> 43 TW Tightening torques - as of MY 2003 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne Turbo). (Scheme 36)

If a new self-levelling sensor is installed, then the control unit for level adjustment must be calibrated.

Designation Type Number Explanation Socket wrench insert VW-tool 3353 Arm bracket special tool P 9630

Scheme 38

Notes on repairing air-spring struts

Note. As of a mileage of 200,000 Km it is recommended that the air springs be replaced per axle if there is damage to one air spring. If the shock absorbers leak, the complete air spring strut is to be replaced. The oil of the shock absorber can damage the roller. When depressurised, the air spring must not be twisted. There is the danger that the roller in the inside of the air spring will be damaged by bending or folding and thus significantly reduce the running time.

Scheme 39

1. Before loosening the air lines in the installed state, check if the rolling boot is still filled with the residual pressure of approx. 3 bar. To do this, press on the rolling boot of the air spring with your thumb. The rolling boot must give perceptible resistance. If no significant resistance can be felt, the air spring is depressurised and must be replaced along with the residual pressure retaining valve.

The greatest possible care and cleanliness, as well as perfect tools are important requirements for carrying out perfect repairs on air-spring struts. The general and basic rules of safety apply. These are specifically listed here again for repairing air-spring struts.

Thoroughly clean the connection points and their surroundings before loosening them.

Do not use fibre-shedding cloths.

Do not take spare parts out of the packaging until right before installation.

Only use lubricants that have part numbers.

Carefully cover open components or close them if the repair work will not be carried out immediately.

Do not use an impact bolter.

Observe correct tightening torques. --> 43 TW Tightening torques - as of MY 2003 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) .

Gaskets, sealing rings and bellows

Always replace sealing rings and bellows.

After removing gaskets, examine the contact surfaces on housings for burrs and damage.

Always loosen and tighten screws or nuts crosswise for mounting covers and housing.

Residual pressure retaining valve

> When loosening the residual pressure retaining valve, lift the vehicle on a platform lift.

> Only leave the vehicle on the platform lift until a new residual pressure retaining valve is installed and the air-spring strut is filled.

Scheme 40

The residual pressure retaining valve may only be replaced if

1 - Residual pressure retaining valve

2 - Socket insert

it was damaged during removal and installation

it was damaged while disassembling and assembling the air-spring strut

the sealing ring is faulty

it does not allow any more air to come out (valve jammed).

If the residual pressure retaining valve is jammed, the vehicle must be lifted for replacement on the platform lift and the wheels must be allowed to turn freely. It must not be compressed with an empty rolling boot.

Tools for repairing air-spring struts

Torque wrench 2-10 Nm (1.5-7.5 ftlb.)

Torque wrench 60-100 Nm (44-74 ftlb.)

Socket wrench insert 3353

Arm bracket P 9630

Checking the air-spring strut

Checking for leaks

1. Dip the filled air-spring strut completely into a water bath.

Note. Before fitting the air-spring strut in the vehicle, carefully blow out and dry all electrical connections and the residual pressure retaining valve with compressed air.

2. There must be no air bubbles rising in the water bath. If no air bubbles can be seen, the air-spring strut can be fitted in the vehicle.

3. If air bubbles appear in the water bath, the air-spring strut must be disassembled again. Replace all sealing rings again. Check the residual pressure retaining valve again visually.

4. Repeat the leak test in the water bath.

Designation Type Number Explanation Socket wrench insert VW-tool 3353 Arm bracket special tool P 9630

Note. As of a mileage of 200,000 Km it is recommended that the air springs be replaced per axle if there is damage to one air spring. If the shock absorbers leak, the complete air spring strut is to be replaced. The oil of the shock absorber can damage the roller. When depressurised, the air spring must not be twisted. There is the danger that the roller in the inside of the air spring will be damaged by bending or folding and thus significantly reduce the running time.

Air-spring strut

1. Before loosening the air lines in the installed state, check if the rolling boot is still filled with the residual pressure of approx. 3 bar. To do this, press on the rolling boot of the air spring with your thumb. The rolling boot must give perceptible resistance. If no significant resistance can be felt, the air spring is depressurised and must be replaced along with the residual pressure retaining valve.

The greatest possible care and cleanliness, as well as perfect tools are important requirements for carrying out perfect repairs on air-spring struts. The general and basic rules of safety apply. These are specifically listed here again for repairing air-spring struts.

Thoroughly clean the connection points and their surroundings before loosening them.

Do not use fibre-shedding cloths.

Do not take spare parts out of the packaging until right before installation.

Only use lubricants that have part numbers.

Carefully cover open components or close them if the repair work will not be carried out immediately.

Do not use an impact bolter.

Observe correct tightening torques. --> 43 TW Tightening torques - as of MY 2003 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) .

> When loosening the residual pressure retaining valve, lift the vehicle on a platform lift.

> Only leave the vehicle on the platform lift until a new residual pressure retaining valve is installed and the air-spring strut is filled.

The residual pressure retaining valve may only be replaced if

1 - Residual pressure retaining valve

2 - Socket insert

it was damaged during removal and installation

it was damaged while disassembling and assembling the air-spring strut

the sealing ring is faulty

it does not allow any more air to come out (valve jammed).

If the residual pressure retaining valve is jammed, the vehicle must be lifted for replacement on the platform lift and the wheels must be allowed to turn freely. It must not be compressed with an empty rolling boot.

Always replace sealing rings and bellows.

After removing gaskets, examine the contact surfaces on housings for burrs and damage.

Always loosen and tighten screws or nuts in diagonally opposite sequence for mounting covers and housing.

Torque wrench 2-10 Nm (1.5-7.5 ftlb.)

Torque wrench 60-100 Nm (44-74 ftlb.)

Socket wrench insert 3353

Arm bracket P 9630

Checking for leaks

1. Dip the filled air-spring strut completely into a water bath.

Note. Before fitting the air-spring strut in the vehicle, carefully blow out and dry all electrical connections and the residual pressure retaining valve with compressed air.

2. There must be no air bubbles rising in the water bath. If no air bubbles can be seen, the air-spring strut can be fitted in the vehicle.

3. If air bubbles appear in the water bath, the air-spring strut must be disassembled again. Replace all sealing rings again. Check the residual pressure retaining valve again visually.

4. Repeat the leak test in the water bath.

Scheme 41

1. Raise vehicle at the jacking points provided --> 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 right cover. Refer to 51 93 19 Removing and installing middle cover - as of MY 2003 (All Models) .

Removing the compressor

The compressor -3- is only installed for the level adjustment system and is attached as a compact air supply unit with valve block -4- on a vibration-insulated support to the right underbody. see scheme 51

1- - Air-spring strut, front axle

2- - Air-spring strut, rear axle

3- - Compressor

4- - Valve block

Scheme 42

> Wear protective goggles.

Note. Place the take-up plates of the platform lift at the jacking points so that the fastening points of the underbody panel are accessible --> 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) (see Switching off level adjustment). To bleed the level adjustment system (compressed air must be released from the system), use the Porsche System Tester. To do this, in the system >> Level adjustment >> select the menu item >>Bleed << and bleed the accumulator, and front and rear axles. Clean the screw connection of the lines from the valve block before removing. Protect the screw connection of the lines from dirt with suitable plugs.

Scheme 43

1. Unclip the suction line and the plug connections -arrows-. see scheme 52

Scheme 44

2. Remove the air lines (color-coded) from the valve unit and the brown air line (running under the valve unit). see scheme 54

Scheme 45

3. Release the mounting points on the body -A, B & C- and remove the compressor unit (compressor, valve block). (Scheme 42)

Disconnect compressor from the valve unit

1. Release the tie-wrap and attachment at the support
2. Unclip the air line and remove
3. Remove the compressor from the support.

Installing the compressor

Note. Install in reverse order. The air lines are colored and designated with letters. Pay attention to cleanliness, if necessary clean the screw connections of the air lines with a lint-free cloth. Visually inspect all parts. Replace locking screws and nuts. Pay attention to tightening torques --> 43 TW Tightening torques - as of MY 2003 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) . To fill the level adjustment system, use the Porsche System Tester. To do this, in the system >> Level adjustment >> select the menu item >> Fill <<; then fill the front and rear axles and the accumulator. Switch on level adjustment --> 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) (see Switching on level adjustment).

1. Fit compressor on the support, clip in the line, and fasten the cable.

2. Insert compressor unit and mount on the body -(A, B & C)-. (Scheme 43)

3. Fit the --> Air lines for valve block air lines to the valve block. (Scheme 44)

1- - black

2- - lilac

3- - blue

4- - green

5- - red

6- - yellow

7- - brown

4. Fit the suction lines and the plug connections.

5. Fill the pneumatic system using the Porsche System Tester.

Subsequent work

Fit right cover Refer to 51 93 19 Removing and installing middle cover - as of MY 2003 (All Models) .

Designation Type Number Explanation PIWIS Tester special tool P 9718

Scheme 46

> Before removing the control module, switch off the ignition and remove the ignition key.

Note. The control module is located behind the right rear side section trim.

Installation Location

Scheme 47

1. Remove the cover of the right rear side section trim.

2. Remove warning triangle and emergency kit.

Scheme 48

3. Pull up the clip of the control module holder and tilt the control module out of the holder.

4. Pull the latch of the upper electrical plug upwards -a- and remove plug. see scheme 59

Scheme 49

5. Pull out control module and pull the latch on the electrical plug -a- and remove plug. see scheme 60

Scheme 50

1. First place the smaller plug on the control module and slide in the latch -a-. (Scheme 46)

Scheme 51

2. Position the control module in the installation position and insert the second plug on the control module and lock it -a-. (Scheme 47)

3. Code level control module. > 431619 Removing and installing level control system control module - "Coding"

4. Calibrate the level control module > 431619 Removing and installing level control system control module - "Calibrating"

5. Insert the control module into the holder and position with the clip.

6. Store the emergency kit and warning triangle and place on the cover of the right rear side section trim.

Note. During coding, it is essential to guarantee the power supply for the The PIWIS Tester P 9718 instructions take precedence and in the event of a discrepancy these are the instructions that must be followed. Deviations may occur with later software versions. The procedure described here has been structured in general terms; different text or additions may appear in the PIWIS tester P 9718 . PIWIS Tester P 9718 . It is essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery.

1. Connect the PIWIS tester P 9718 to the vehicle and start it. Switch on the ignition. >> Continue.

2. Select vehicle type using the cursor keys.

3. Using the >> key, move from the vehicle type to the list of control modules.

4. Select Level control and press the >>.

5. Select Coding and press the >>.

6. Select Select country and code with the F8.

7. Read out fault memory and erase if required.

Note. During coding, it is essential to guarantee the power supply for the The PIWIS Tester P 9718 instructions take precedence and in the event of a discrepancy these are the instructions that must be followed. Deviations may occur with later software versions. The procedure described here has been structured in general terms; different text or additions may appear in the PIWIS tester P 9718 . PIWIS Tester P 9718 . It is essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery.

Information, measuring points, procedure, and conditions for calibration: --> Calibration .

1. Connect the PIWIS tester P 9718 to the vehicle and start it. Switch on the ignition. >> Continue.

2. Select vehicle type using the cursor keys.

3. Using the >> key, move from the vehicle type to the list of control modules.

4. Select Level control and press the >>.

5. Select Actual values and press the >>.

6. Select the Actual values menu and display the safety code. Then read out the safety code and make note of it.

7. Select the menu Calibration , enter the safety code and carry out the Calibration function. Follow the instructions on the PIWIS tester.

8. Read out fault memory and erase if required.

Designation Type Number Explanation insert part VW-tool T10212

Scheme 52

Preliminary work

> 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.

The relevant wheel must be removed when carrying out repairs to avoid damaging the drive shaft.

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

Removing rear spring strut

Installation Location

Scheme 53

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. Fit protective tube on drive shaft (shop-made to protect the drive shaft).

Scheme 54

3. Loosen pressure line on residual pressure retaining valve -arrow- using insert part T10212 (front spring strut connection in figure). Then, unclip the pressure line from the holders and set it aside. (Scheme 50)

Scheme 55

4. Remove stone guard for CDC sensor -arrow-. (Scheme 51)

Scheme 56

5. Disconnect CDC sensor plug connection -arrow-, remove the cable from the holder, and set the cable aside. (Scheme 52)

Scheme 57

6. Remove the fastening screw for the connecting link/spring strut on the wheel carrier. To do this, use a suitable lift with rubber base in order to prevent slipping. Lay the connecting link aside. (Scheme 53)

Scheme 58

7. Remove the four fastening screws (top) -arrows-. see scheme 69

Scheme 59

8. Carefully remove spring strut downwards -arrow-. (Scheme 54)

Scheme 60

> 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. 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. 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 is being raised with a universal vehicle lift! Dimension -X-, from lower edge of wing to middle of axle 506 mm ± 10 mm corresponds to vehicle position! (Scheme 56) Carry out a visual inspection of all parts! Replace self-locking nuts! 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 all expansion screws (screws which are fitted with torque angle tightening procedure)! Use correct tightening torques and torque angle! Refer to 42 TW Tightening torques for rear axle - as of MY 2003 (All Models).

Scheme 61

1. Insert spring strut into vehicle.

2. Fit the four fastening screws -arrows-. (Scheme 57)

Scheme 62

3. Carefully raise the air spring strut using a suitable lift with rubber base. Then, pull the wheel carrier downwards in order to fit the fastening screw. (Scheme 58)

Scheme 63

4. Attach the fastening screw for the connecting link/spring strut -arrow- to the wheel carrier. (Scheme 59)

Scheme 64

5. Connect the CDC sensor plug connection to the lower part of the spring strut -(arrow)-. Insert cable into the holders. (Scheme 60)

6. Fit stone guard for CDC sensor -arrow-. (Scheme 61)

7. Fit pressure pipe to residual-pressure retaining valve using insert part T10212 > Tightening torques [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1] . Then clip the pressure line into the retaining devices.

8. Remove protective tube from drive shaft.

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

2. To fill the air suspension (the system must be filled with compressed air), use the -Porsche System Tester-. To do this, select the menu item Fill air suspension in the Air suspension system. (Scheme 62)

3. 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) .

Designation Type Number Explanation protective tube (shop made) commercially available tool 00000 puller hook special tool 9229 universal drive shaft/wheel hub puller as of model '86 commercially available tool NR.87-1 press-out tool VW-tool T10187 assembly fixture VW-tool T10206 insert part VW-tool T10212 spring compressor VW-tool VW 552

Scheme 65

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

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

3. Remove hub cap using puller hook 9229 and undo drive shaft fastening at the side of the wheel before raising the vehicle. Operate the brake whilst doing so (second fitter required).

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

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) .

Removing

Front sensor

Scheme 82

1. First push together the sensor connector -arrow- firmly (makes removal easier!). Lift connector lock and then remove connector! (Scheme 80)

2. Loosen screw of holder and remove sensor.

Rear sensor

Scheme 83

1. First push together the sensor connector -arrow- firmly (makes removal easier!). Lift connector lock and then remove connector! see scheme 108

2. Loosen nut of holder and remove sensor.

Installing

Front sensor

1. Insert sensor with holder in the correct position -arrow- and tighten the fastening screw. see scheme 109

2. Plug in connector. Pay attention to correct line routing.

Rear sensor

1. Insert sensor with holder in the correct position -arrow- and tighten the fastening nut. see scheme 110

2. Plug in connector. Pay attention to correct line routing.

Front sensor

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

Rear sensor

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

Scheme 84

Cutters VAS 6228 00000 for cutting through pressure hose.

Notes on replacing pressure hoses

Note. Faulty pressure hoses can be replaced in sections. Using a plug connection (see Spare Parts Catalogue), individual sections of pressure hoses can be safely joined again. The pressure hoses are correctly fitted when the first color marking (self applied) is no longer visible and the second color marking is still visible. To check that the pressure hose is fitted correctly, pull it slightly against the insertion direction. If it is fitted correctly, it cannot be pulled out or only pulls out when great force is applied.

Scheme 85

The following points must be observed when choosing the repair point

The repair point must lie in an area protected from water spray

The push-on connector must be fastened with tie-wraps to the structure or a cable guide

Straight pipe sections should be chosen for the repair

Position the pressure hose back in its original fastenings

Insert the ends of the pressure hoses firmly into the push-on connector.

Repair

Note. When filling the air suspension, the vehicle lifts.

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. To bleed the air suspension (air pressure must be allowed to escape out of system - if this has not already happened due to the faulty line), use the Porsche System Tester. To do this, select the menu item Bleed air suspension in the Air suspension system.

3. When repairing the pressure hose, cut off the damaged section squarely using the cutters cutters VAS 6228 00000 .

4. Mark the pressure hose to be replaced in color (e. g. with a waterproof marker). Measured from the cut-off end of the hose, make two colored marks at 16 mm and 22 mm respectively -(arrows)-. (Scheme 83)

5. Insert the pipe until the range between the two color markings min. 16 mm up to max. 22 mm -(arrows)- has been reached. (Scheme 83)

To fill the air system, use the Porsche System Tester. To do this, select the menu item Fill air suspension in the Air suspension system. Switch on level adjustment --> 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) .

Poses Online