Level Control: Overhaul Porsche Cayenne I

Disassembling spring strut

> Always unscrew the screws on the mounting saddle by one turn only, on alternating sides. During disassembly, allow the air to escape by tilting the mounting saddle slightly.

Scheme 11

1. Clamp the air-spring strut on the lower mounting point (use aluminum protective jaws -A-!). see scheme 21

2. Loosen the fastening screws on the mounting saddle.

Scheme 12

3. Carefully remove the mounting saddle over the residual pressure retaining valve in direction of arrow.

Scheme 13

4. Remove spring-strut mount with socket wrench insert 3353 and arm bracket P9630.

Scheme 14

5. Remove clamp.

Note. When replacing the air spring, always replace the boot/bellows. If the rolling piston slips out of the outer guide during disassembly, it must be correctly positioned again when assembling. When sliding in the rolling piston, the roller must lie evenly between the outer guide and rolling piston (roll fold).

Scheme 15

6. Push bellows downward and secure in this position (2nd worker required!). Grasp the rolling piston and remove it upward from the shock absorber by slightly turning to the left/right.

Scheme 16

7. When replacing the air spring, push the rubber stop -1- out of the centring device. (Scheme 14)

8. Remove boot/bellows.

9. When replacing the shock absorber, remove the cap and fit it on the new shock absorber.

Assembling spring strut

Note. When replacing the air spring, always replace the boot/bellows. If the rolling piston slips out of the outer guide during disassembly, it must be correctly positioned again. When sliding in the rolling piston, the roller must lie evenly between the outer guide and rolling piston (roll fold). 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 with Syntheso Glep 1 (ET No. 000.043.204.68).

If the shock absorber is not replaced, the sealing ring must be replaced.

Scheme 17

1. Replace sealing ring on shock absorber -Arrow-. (Scheme 15)

2. Pull boot/bellows completely over the collar of the shock absorber so that it engages (small diameter downward, 2nd worker required).

3. Fit rubber stop (small diameter downward).

Scheme 18

4. Position the air spring on the shock absorber. Grasp the rolling piston and push downward by turning it slightly to the left and right. If the rolling piston has slipped out of the outer guide, it must be pushed back in again while forming a circumferential uniform roll fold on the rolling boot -Arrows-. (Scheme 16)

Scheme 19

5. Clean the surfaces -2- on the mounting saddle and on the air spring with a lint-free cloth. Replace sealing ring -1- on the air spring. (Scheme 17)

Scheme 20

6. Align the air spring so that the residual pressure retaining valve is located close to the imaginary axis of symmetry (approx. 10° off-center) of the air-spring strut.

7. Fit bellows (large diameter up).

8. Fit spring-strut mount with socket wrench insert 3353 and arm bracket P9630.

Scheme 21

9. Fit mounting saddle and while doing so align it so that the upper arm of the bearing points to the residual pressure retaining valve.

10. Fill the air-spring strut. --> 43 01 IN Filling specification for air-spring strut - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

> Always unscrew the screws on the mounting saddle by one turn only, on alternating sides. During disassembly, allow the air to escape by tilting the mounting saddle slightly.

Scheme 22

1. Clamp the air-spring strut on the lower mounting point (use aluminum protective jaws -A-!). see scheme 37

2. Loosen the fastening screws on the mounting saddle and carefully remove the mounting saddle.

3. Remove spring-strut mount with socket wrench insert 3353 and arm bracket P 9630.

4. Remove clamp.

Note. When replacing the air spring, always replace the boot/bellows. If the rolling piston slips out of the outer guide during disassembly, it must be correctly positioned again when assembling. When sliding in the rolling piston, the roller must lie evenly between the outer guide and rolling piston (roll fold).

5. Push bellows downward and secure in this position (2nd worker required!). Grasp rolling piston -1- and remove it upward from the shock absorber by turning slightly to the left/right. (Scheme 22)

6. When replacing the air spring, push the rubber stop -1- out of the centring device. see scheme 41

7. Remove boot/bellows.

Scheme 23

8. When replacing the shock absorber, remove the wheel acceleration sensor -1- and fit it on the new shock absorber. see scheme 42

Note. When replacing the air spring, always replace the boot/bellows. If the rolling piston slips out of the outer guide during disassembly, it must be correctly positioned again. When sliding in the rolling piston, the roller must lie evenly between the outer guide and rolling piston (roll fold). 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 with Syntheso Glep 1 (ET No. 000.043.204.68).

If the shock absorber is not replaced, the sealing ring must be replaced.

1. Replace sealing ring on shock absorber -Arrow- (figure shows rear shock absorber). see scheme 43

2. Pull boot/bellows completely over the collar of the shock absorber, so that it engages (small diameter downward, 2nd worker required).

3. Fit rubber stop (small diameter downward).

4. Position the air spring on the shock absorber. Grasp the rolling piston and push it downward by turning it slightly to the left and right. If the rolling piston has slipped out of the outer guide, it must be pushed back in again while forming a circumferential uniform roll fold on the rolling boot -Arrows-. see scheme 44

5. Clean the surfaces -2- on the mounting saddle and on the air spring with a lint-free cloth. Replace sealing ring -1- on the air spring. (Scheme 23)

Scheme 24

Note. To align the air spring, carefully turn the rolling piston in order to not damage the roller.

6. Fit and align the air spring. While doing so, the residual pressure retaining valve -1- must be located exactly at the imaginary axis of symmetry -Arrow- of the air-spring strut. The residual pressure retaining valve must be facing in the opposite direction to the CDC valve. see scheme 46

7. Fit bellows at the top.

8. Fit spring-strut mount using socket wrench insert 3353 and arm bracket P9630.

Scheme 25

9. Fit mounting saddle -Screws A- and align it so that the upper arm of the bearing -B- points to the residual pressure retaining valve. see scheme 48

Scheme 26

10. Align the air spring again so that the residual pressure retaining valve is located exactly at the axis of symmetry -Arrow- of the air-spring strut. (Scheme 24)

11. Fill the air-spring strut. --> 43 01 IN Filling specification for air-spring strut - as of MY 2003 (All Models Except Cayenne S TIO Titan) .