Assembling Rear Spring Strut (Steel Springs)

Information 

If the coil spring is replaced: Always replace coil springs in pairs only!

Information 

• The coil springs are allocated using the spare part numbers and the model specification. Various coil springs are used at present on the rear axle of the Cayenne. Refer to the Parts Information for details of allocation. 
• The shock absorbers are allocated using the spare part numbers and the model specification. Various shock absorbers are used at present on the rear axle of the Cayenne. Refer to the Parts Information for details of allocation. 
• The spacers are allocated based on the different tolerance groups. 0, 1 or 2 spacers are used. The number depends on the number of violet dots on the coil spring. 
• Observe correct tightening torques. 

  > WM, 4X00IN TIGHTENING TORQUES FOR REAR AXLE

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

1. Place the cap -1-  , washer (no longer used from model year B onwards) -2-  , rubber stop -3-  and boot -4-  together as follows before pushing them onto the piston rod:

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   Cap, washer, rubber stop and boot assembly

   1. 1.1 Push the rubber stop -3-  up fully into the protective sleeve -4-  .
   2. 1.2 Check that the washer  -2-is seated correctly! 

      On conventional shock absorbers, the washer must be fitted over  the stop cap.

      On shock absorbers with PASM, the washer must be fitted under  the stop cap.

   3. 1.3 Insert the washer -2-  as described in Step 1.2 and the cap -1-  into the boot - see figure-  and pull the lip carefully over the cap.

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   Fitting cap into boot

2. Fit the bottom concave washer - see figure-  and the bottom support - see figure-  together at the correct position (not twisted). (Align triangular markings all the way around).

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   Fitting lower concave washer into lower support

3. Fit the top concave washer -1-  and the top support -2-  together at the correct position (not twisted). (Align triangular markings all the way around).

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   Fitting upper concave washer with upper support

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 colour marking must be on the bottom spring coils.

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   Coil spring stop in lower concave washer

7. Slide the boot/rubber stop/washer, if necessary and cap assembly loosely onto the piston rod. If there is a washer (no longer used from model year B onwards), check that the washer is on the piston rod!
8. Fit the top concave washer/top support assembly.

   Position the top spring plate precisely at the coil spring stop -arrow-  .

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   Upper spring support stop on coil spring (shown as an example)

9. Position the concave support in such a way that the centre lines -A-  and -B-  are parallel.

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   Concave support assembly

10. Fit the supporting mount and tighten the new lock nut slightly.
11. Final alignment of concave support 
    1. 11.1 Right spring strut: Turn the concave support 16° +/-1° clockwise  (-A-  ). In other words: imagine a clock, for example, and turn the concave support clockwise for 2 - 3 minutes on an imaginary line from 9 o'clock to 3 o'clock.
    2. 11.2 Left spring strut: Turn the concave support 16° +/-1° anti-clockwise  . In other words: imagine a clock, for example, and turn the concave support anti-clockwise for 2 - 3 minutes on an imaginary line from 9 o'clock to 3 o'clock.

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    Aligning concave support on right spring strut

12. Finally fit the lock nut using > 3353 - socket-wrench insert or for PASM, > 3077 - socket-wrench insert.
13. 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.

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    Fitting boot in upper spring strut (shown as an example)

    Push the boot down fully and pull the cap on the shock absorber down -arrow-  .

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    Fitting boot in lower spring strut (shown as an example)

14. Fit the cover (for PASM, check the position of the cable holder!) and secure with four nuts -1-  .

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    Fitting cap

15. On vehicles with PASM, fit the grommets -1-  onto the cable by opening the grommets slightly using a commercially available Seeger circlip ring pliers. This makes it easier to push the pins through the grommets.

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    Fitting grommets

16. On vehicles with PASM, pin the cables into the connector (according to markings applied earlier) and close the locking mechanism.
17. On vehicles with PASM, fit the cable guide and move the grommets to the correct position at both ends of the cable.

    Check that the cable guide is aligned at the correct position > Cable guide alignment  . In other words, the cable guide must be facing towards the cable holder.

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    Cable guide alignment