429019 Removing and installing rear anti-roll bar (PDCC)
WM 429019 Removing and installing rear anti-roll bar (PDCC)
Preliminary work
1. Raise the vehicle at the jacking points provided -> 40 Lifting the vehicle.
2. Remove the rear silencer -> 260119 Removing and installing exhaust system - section on "Removing" Service and Repair.
General warning notes
CAUTION
Twisted, chafed and kinked steel flexi-pipes and/or expansion hoses.
- Risk of PDCC system failure due to reduced line cross sections and leaking lines.
-> Steel flexi-pipes and expansion hoses must not be disconnected or kinked.
-> Always replace steel flexi-pipes and expansion hoses if you suspect that they have been damaged.
-> Twisted steel flexi-pipes and expansion hoses must not be fitted.
-> Steel flexi-pipes and expansion hoses must have sufficient clearance from other components.
-> Steel flexi-pipes and expansion hoses must only be fitted using the mounting elements provided for this purpose. Do not use tie-wraps or screw-type clamps.
Information
Before starting to work on the PDCC system, always clean the underbody or at least clean the system components you will be working on. Ensure absolute cleanliness at all times. In other words:
- Clean the system components to be removed using a power washer, for example. Ensure that the high-pressure spray is at least 50 cm away from the component (risk of damage to electric lines, connectors and contacts).
- Before loosening the hydraulic connections, the areas around the connections must also be cleaned carefully (e.g. using a brush and/or a lint-free cloth).
- If you intend to use the component again, the openings must be sealed immediately with suitable stoppers.
- If you are using new components, the stoppers must only be removed immediately before fitting.
Removing rear anti-roll bar (PDCC)
Rear anti-roll bar
PDCC component arrangement
1. Mark the two lines using a touch-up stick, from the steel flexi-pipe to the anti-roll bar housing => Marking on rear anti-roll bar.
Marking on rear anti-roll bar
2. Mark the installation position -arrow- of the anti-roll-bar mount halves with respect to the anti-roll bar with a touch-up stick.
3. Support the anti-roll bar in the middle with a transmission jack (use a suitable rubber base) and loosen the four fastening points evenly. Carefully lower the anti-roll bar by approx. 10 cm.
Supporting the anti-roll bar
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.
4. Loosen the two lines on the anti-roll bar using an open-ended wrench. Use a container to collect emerging fluid and close the lines using suitable plugs.
5. Loosen the connecting links at the left and right of the anti-roll bar. Carefully remove the anti-roll bar while taking care not to damage adjacent components.
Installing rear anti-roll bar (PDCC)
Rear anti-roll bar
CAUTION
Increased risk of accidents if the wheel carrier is raised improperly.
- Injury and material damage possible.
-> 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.
1. Mount the anti-roll bar halves at the correct position on the anti-roll bar => see figure. The correct position means the larger outer diameter is on the wheel side.
2. Engage the anti-roll-bar mount halves at the prescribed mounting points -arrow-.
3. Mount the anti-roll bar on the connecting links.
4. Support the anti-roll bar in the middle with a transmission jack (use a suitable rubber base) and raise it carefully until approx. 10 cm from installation position. Fit the steel flexi-pipes loosely.
Supporting the anti-roll bar
5. Tighten the two steel flexi-pipes (observe markings => Marking on rear anti-roll bar .).
Marking on rear anti-roll bar
Information
- 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.
- Visually inspect all parts.
- Replace self-locking nuts.
- Replace all expansion screws (screws which are fitted with torque angle tightening procedure).
- Observe tightening torques -> 42 Tightening torques for rear axle.
6. Fit the anti-roll bar and secure the four mounting points evenly, in vehicle position.
7. Following assembly, check carefully once again that the steel flexi-pipes are not twisted. The toothed rings 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
Subsequent work
1. Fit the rear silencer -> 260119 Removing and installing exhaust system - section on "Installing" Service and Repair.
2. Complete the following steps in sequence using the PIWIS System Tester by selecting PDCC >> System replacement ]] Replace anti-roll bars [[: -> 4303AW Safety requirements for Porsche Dynamic Chassis Control (PDCC) Service Precautions
2.1. Set valve timing
2.2. Bleed the system -> 430307 Bleeding Porsche Dynamic Chassis Control (PDCC) 430307 Bleeding Porsche Dynamic Chassis Control (PDCC)
2.3. Carry out a system test.