Assembling Front Spring Strut

Information

When replacing the air spring, always replace the boot/bellows.

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

Always loosen and tighten screws and nuts crosswise for mounting covers and housings.

When sliding in the rolling piston, the convoluted air bellows must lie evenly between the outer guide and rolling piston (roll fold).

Information

If you are not replacing the shock absorber, the sealing rings and safety catch must be replaced.

Make sure that everything remains absolutely clean. The smallest impurities can cause leakages.
Clean the contact surfaces of the sealing rings with a lint-free cloth.
Lightly grease sealing rings and safety catch with Sticks Syntheso Glep 1 (Part No. 000.043.204.68).

Information

The pictures shown in this document may differ from the original.

Installation is performed in reverse order.

Observe the specified tightening torque:

Supporting mount to piston rod: > Tightening torque 70 Nm (52 ftlb.) +/- 5 Nm (3.5 ftlb.)

Check all components for damage and soiling (especially all sealing components).
Replace the large ring (O-ring) in the groove on the adapter ring (welded ring). -arrow-

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Adapter ring (welded ring) with large ring (O-ring)
Always replace safety catch -1- and slide it on as far as the support ring -2- .

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Always replace safety catch

Information

Additional spring defective
- If the additional spring is defective, the complete air spring must be replaced.

When replacing air springs

Check that the additional spring is fitted at the correct position -arrow- . See also illustration under Component overview "Spring strut, cut-out view", item 7.

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Installation position of additional spring

1	Additional spring
2	Air spring
arrow	Centering device

Information

Additional spring defective

If the additional spring is defective, the complete air spring must be replaced.

When replacing the air spring, slide the additional spring -1- into the Centering device. Check that it is installed at the correct position.

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Centering device for additional spring 1 in air spring 2 (shown as an example)
Slide the hose (shop-made) onto the hexagon on the piston rod (shown with air spring fitted!). Then fit the air spring. > Hose (shop-made)

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Hose (shop-made)
Remove the hose (shop-made). -arrow-

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Replacing small ring (O-ring)
1. 7.1 To protect the O-ring, mask the thread of the shock absorber. Fit small ring (O-ring) on the piston rod. -arrow-
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Fitting O-ring and masking thread

Align the air spring so that the push-on connector for the pressure control valve is located exactly at the axis of symmetry of the shock absorber. Fit shock absorber mounting. > Aligning air spring

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Aligning air spring

If the air spring was rolled up by mistake, check that the roll fold is even all around the rolling piston. -arrows-

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Roll folds

Information
- Make sure that everything remains absolutely clean. The smallest impurities can cause leakages.
- Clean the contact surfaces of the sealing rings with a lint-free cloth.
Fit upper air-spring strut -1- and fit the boot/bellows loosely on the air spring!
1. 8.1 Guide the wire harness through the opening in the spring strut mount. Insert the upper air-spring strut into the vehicle and fit it (boot/bellows only fitted loosely on the air spring!).
2. 8.2 Do not trap the air line while doing this.
  > 433019 REMOVING AND INSTALLING FRONT SPRING STRUT (AIR SPRINGS)
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Installing spring strut
Fit grommets on the cables using Seeger circlip pliers. -Grommets-
Fit the cables at the same position in the connector according to the cable routing you noted earlier.

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Opening grommet slightly using Seeger circlip pliers
Lift the wheel bearing housing. Do not damage the brake cover plate.

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Supporting wheel bearing housing (example)

Raise the axle until the screw for the spring strut prongs and the upper wishbone can be inserted on the wheel carrier.

11.1 With the axle raised further, jiggle it continuously at the rolling piston and turn it back and forth slightly.

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Rolling piston for air-spring strut

1	Rolling piston
2	Air spring

11.2 The safety catch is touching the air-spring rolling piston. Raise it further and press the safety catch into the air-spring rolling piston using a plastic wedge if necessary. -Safety catch-

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Raising shock absorber with safety catch into the air-spring rolling piston

11.3 Raise the axle further until the safety catch in the rolling piston is no longer visible. -arrow-

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Raise the shock absorber with safety catch into the rolling piston. The following are still visible: Shock absorber with adapter ring (welded ring) with large ring (O-ring)

11.4 Raise the axle further until the adapter ring (welded ring) with the large ring (O-ring) on the shock absorber pipe disappears by about 3 mm into the rolling piston. -Rolling piston-

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Raising shock absorber until adapter ring (welded ring) with large ring (O-ring) disappears by about 3 mm

Push the pressure control valve open using a 5-mm Allen key and keep it open. Then carefully lower the axle until it is suspended freely. This allows air to flow in and prevents folds from developing in the air spring.
Fit the air line and fill the air-spring strut to about 2 bar overpressure using the filling routine on the Porsche System Tester.
Check that roll folds are formed evenly in the rolling piston. -arrows-

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Roll folds
Finally fit the boot/bellows and spring strut.
> 433019 REMOVING AND INSTALLING FRONT SPRING STRUT (AIR SPRINGS)