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 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.

The next sections describe the spring struts with and without PASM.

1. Replace the large ring (O-ring) in the groove on the adapter ring (welded ring). -arrow- 
   Fig 1: Locating Adapter Ring With Large Ring (Welded Ring)

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2. Always replace the safety catch and slide it on as far as the adapter ring (welded ring). -arrow- 
   Fig 2: Replacing Safety Catch (Welded Ring)

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3. For replacing air spring 

   Information 

   Additional spring defective

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

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

   1. Additional spring
   2. Air spring

   Arrow  - Centering device

   Fig 3: Identifying Installation Position Of Additional Spring

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   Information 

   Additional spring defective

   • If the additional spring is defective, the complete air spring must be replaced  .
4. When replacing the air spring, slide the additional spring -1-  into the centering device. Make sure that it is installed at the correct position.
   Fig 4: Centering Device For Additional Spring 1 In Air Spring 2

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5. For PASM: Before fitting the air spring  , slide a piece of hose (shop-made) onto the hexagon on the piston rod (air spring shown fitted!). Then fit the air spring. → Hose (shop-made) 
   Fig 5: Sliding Hose (Shop-Made)

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6. Remove the hose (shop-made). -arrow- 
   Fig 6: Replacing Small Ring (O-Ring)

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   1. 6.1. To protect the O-ring, mask the thread of the shock absorber. Fit small ring (O-ring) on the piston rod. -arrow- 
      Fig 7: Fitting O-Ring And Masking Thread

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      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 

      Fig 8: Aligning Air Spring

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

      Fig 9: Locating Roll Folds

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      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  .
7. Fit upper air-spring strut -1-  and fit the boot/bellows loosely on the air spring!
   1. 7.1. 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. 7.2. Do not trap the air line while doing this. → 433019 REMOVING AND INSTALLING FRONT SPRING STRUT (AIR SPRINGS) 
      Fig 10: Installing Spring Strut

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8. Fit the grommets on the cables using a Seeger circlip ring pliers.

   -grommets- 

   Fit the cables at the same position in the connector according to the cable routing you noted earlier.

   Fig 11: Opening Grommet Slightly Using Seeger Circlip Ring Pliers

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9. Lift up the wheel bearing housing. Do not damage the brake cover plate.
   Fig 12: Lifting Wheel Bearing Housing (Rear Axle)

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10. Raise the axle until the screw for the spring strut prongs and the upper control arm can be inserted on the wheel carrier.
    1. 10.1. With the axle raised further, jiggle it continuously at the rolling piston and turn it back and forth slightly.
       1. Rolling piston
       2. Air spring
          Fig 13: Air-Spring Strut Rolling Piston

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    2. 10.2. 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- 
       Fig 14: Raising Shock Absorber With Safety Catch In Air-Spring Rolling Piston

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    3. 10.3. Raise the axle further until the safety catch in the rolling piston is no longer visible. -arrow- 
       Fig 15: Raising Shock Absorber With Safety Catch In Rolling Piston

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    4. 10.4. 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- 
       Fig 16: Raising Shock Absorber Until Adapter Ring (Welded Ring)

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11. 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.
12. Fit the air line and fill the air-spring strut to about 2 bar overpressure using the filling routine on the Porsche System Tester.
13. Check that roll folds are formed evenly in the rolling piston. -arrows- 
    Fig 17: Locating Roll Folds

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