Assembling Front Spring Strut (Steel Springs)

→ Do not reach into the danger area.

→ Relieve the tension on components before starting work.

→ Secure components to prevent them from loosening suddenly.

Information 

• The coil springs are allocated using the spare part numbers and the model specification. Various coil springs are used at present on the front axle of the Cayenne.  
• The shock absorbers are allocated using the spare part numbers and the model specification. Various shock absorbers are used at present on the front axle of the Cayenne. 
• Observe correct tightening torques  . → 4X00IN TIGHTENING TORQUES FOR FRONT AXLE

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

1. Assemble the cap -1-  , rubber stop -2-  and boot -3-  as follows before pushing them onto the piston rod:
   Fig 1: Identifying Cap, Rubber Stop And Boot

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   • Push the rubber stop -2-  up fully into the protective sleeve -3-  .
   • Insert the cap into the boot -see Fig 2- and pull the lip carefully over the cap.
     Fig 2: Fitting Cap Into Boot

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2. Assemble the bottom concave washer (the -arrows-  must be aligned) with the bottom support at the correct position.
   Fig 3: Fitting Bottom Concave Washer Into Bottom Support

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3. Assemble the top concave washer with the top support -see figure-Fig 4 at the correct position (not twisted).

   At the correct position means both individual components joined together.

   Fig 4: Fitting Top Concave Washer In Top Support

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4. Fit the spacer(s) on the shock absorbers if necessary, depending on the vehicle.
5. Fit the bottom support and bottom concave washer assembly at the correct position on the shock absorber.
6. Position the pre-tensioned coil spring precisely at the stop in the bottom concave washer -arrow-  .

   The color marking must be on the bottom spring coils.

   Fig 5: Locating Coil Spring Stop In Bottom Concave Washer

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7. Slide the boot/rubber stop/cap assembly loosely onto the piston rod.
8. Fit the top concave washer/top support assembly.
   • Fit the top spring support precisely (without gaps) at the coil spring stop -arrow-  .
     Fig 6: Fitting Top Spring Support Precisely (Without Gaps)

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9. For assembly, observe the markings made earlier for the concave support, steel spring and shock absorber. → Spring strut marked 
   Fig 7: Identifying Spring Strut Marked

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10. Fit supporting mount.
    1. 10.1. Align the shock absorber so that the connecting link connection from the anti-roll bar to the spring strut is facing in the opposite direction to the direction of travel.
11. Align the opposite notches -inset-  of the supporting mount parallel to the direction of travel.
    1. 11.1. Small notch on the left must always be facing forward and to the left in direction of travel. Spring strut, LEFT  : → Supporting mount alignment, LEFT 
       Fig 8: Supporting Mount Alignment - Left

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    2. 11.2. Small notch on the left must always be facing forward and to the left in direction of travel. Spring strut, RIGHT  : → Supporting mount alignment, RIGHT 
       Fig 9: Supporting Mount Alignment - Right

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12. Screw lock nut onto the piston rod.
    1. 12.1. Screw the lock nut onto the piston rod until approx. 1 to 2 threads are visible above the lock nut.
13. Use socket-wrench insert 3353  or for PASM, socket-wrench insert 3077  to tighten the lock nut.

    The tightening torque can vary, depending on the equipment variant: 

    Spring strut without PASM Tightening torque 60 Nm (44 ftlb.) +/-5 Nm (+/-3.5 ftlb.) 

    Spring strut with PASM Tightening torque 70 Nm (52 ftlb.) +/- 5 Nm (+/-3.5 ftlb.) 

    Fig 10: Fitting Supporting Mount

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14. Carefully remove the spring tensioner.
15. Complete the following steps to ensure that the boot is seated correctly:
    • Push the boot up fully -arrow-  and clip it into the concave support.
      Fig 11: Fitting Protective Sleeve In Top Spring Strut

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    • Push the boot down fully and pull the cap on the shock absorber down -arrow-  .
      Fig 12: Fitting Protective Sleeve In Bottom Spring Strut

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16. On vehicles with PASM, fit the grommets on the cable.
17. On vehicles with PASM, pin the cables into the connector (according to markings applied earlier) and close the locking mechanism.