Brakes and Traction Control: Service Precautions

Safety notes and information when repairing the running gear

General warning notes
Fitting vehicle parts

WARNING: Material damage. When mounting specifications are not observed, the long-term behavior of screw-connections is nor ensured.
-> There can be limitations on the service life or function of the components.
-> All parts used on the running gear are subject to a close visual inspection.
-> Only use approved original Porsche parts.
-> Replace self-locking nuts.
-> The prescribed tightening torque must be strictly observed.
-> Observe grease specification (for example, on steering shaft).
-> Ensure that ball joint rod conical seats are clean when fitting. Clean bevel pinions with a lint-free cloth. Do not use cleaning agent.

Spring struts/coil springs

ATTENTION: There will be alterations in handling due to installing incorrect parts.
^ Prior mechanical damage to coil springs due to incorrect handling by the customer or in the workshop can cause the coil springs to break, even at a later point in time.
^ When installing new coil springs/spring struts, make sure they are assigned correctly according to the Spare Parts Catalogue.
^ When removing and installing coil springs, only use suitable or specified tools/spring compressors.
^ No welding, sanding, or separating work in the area of coil springs/spring struts. Cover coil springs/spring struts.

Wheel rims and tires

WARNING: Increased risk of accidents as a result of damage to wheels/tires if handled improperly.
-> Injuries due to the high tire seating pressure required (max. 4 bar! this value must not be exceeded!), cannot be ruled out.
-> Welding on light-alloy wheels can cause bulges, which can cause them to break if they are used.
-> Tires must be filled in the filling cage.
-> If the tires do not jump over at the max. 4 bar, the tires must be pressed off again, and lubricated with new tire paste and then fitted.
-> Straightening and welding work on light alloy wheels is not permissible.

Note:
^ Newly mounted tires require a bedding-in period to remove the vulcanization layer.
^ Customers must be informed that the full performance of new tires is achieved only after a distance of 100 to 200 km (60 to 120 miles) has been driven. Avoid extreme driving maneuvers (acceleration, braking) during this time.

Working on vehicles with PSM

DANGER: Risk of accident due to incorrect functioning of steering angle sensor if it is uncalibrated or incorrectly calibrated.
^ There is a risk of accidents causing physical damage to persons or objects in the PSM testing area.
-> After working on wheel suspension parts, when replacing the steering-angle sensor, and after changing the wheel alignment values, calibrate the steering angle sensor with the front wheels in straight-ahead position using the PIWIS tester.
-> Check the actual value of the steering angle sensor after a suspension alignment where no changes were made to the wheel alignment values.

Brake system

WARNING: Increased risk of accidents and damage to the vehicle if braking effect is impaired by using non type-specific original Porsche spare parts, if the brake pads and/or brake discs are replaced too late.
^ There can be limitations on the service life or function of the components.
-> Use only the type-specific brake pads (correct brake pad quality) in the Porsche Spare Parts Catalogue. When installing a new expanding spring, mount a new retaining pin and new retainer (safety bracket) or retaining pin screw on the brake caliper.
-> After repairs to the brake system, the brake pressure must be built up again by applying the brake pedal several times.
-> The brake pads must be replaced when the brake pad warning indicator lights up, but no later than when there is a residual pad thickness of 2mm.
-> Replace brake discs in good time (observe minimum brake disc thickness and surface condition).

Note:
^ Observe brake fluid quality. Use only new DOT 4 brake fluid.
^ The brake-fluid change interval using Super DOT4 brake fluid is two years.
^ This brake fluid is available under the following part numbers: Container quantity: 1 liter = 000.043.203.66. 30 liters = 000.043.203.67.

Handling air bag systems

WARNING: A triggering of the airbag (malfunction in the airbag system) caused by improper work on airbag components cannot be ruled out.
^ In the case of malfunction, an unsuitable steering wheel holder can cause injury or damage during suspension alignment work.
-> Use only steering wheel holders which do not project into the area of the airbag unit during suspension alignment work.
-> Observe safety regulations for airbag vehicles.

Steering

WARNING: Risk of accidents accompanied by danger of injury and damage to the vehicle due to incorrect handling of Pentosin CHF 11 S.
^ It is possible that the reservoir can overflow while driving if too much Pentosin CHF 11 S is added. Overflowing onto hot components can cause fires.
-> If coolant hoses come into contact with Pentosin CHF 11 S for a longer period of time, they will swell.
-> Observe the MAX.marking.
-> Multiple steering operations (maneuvering) with the engine switched off change the fluid level in the reservoir. The engine must be run for approximately 20 seconds immediately prior to the fluid level check.
-> If coolant hoses come into contact with Pentosin CHF 11 S, thoroughly clean them with water IMMEDIATELY and replace if necessary.

Note: Rack-and-pinion steering gear and servo pump must not be repaired or dismantled.