Assembling Spring Strut

Information 

• When installing new components, always check that they are assigned correctly. 
• Coil springs are only available in pairs. 

1. Clamp the spring strut at a suitable place in the vice (use jaw liners).
2. When replacing the vibration damper, fit a new snap ring -10-  - using snap-ring pliers VW 161 A  - in the relevant groove -A or B-  (see allocation in next table).

   Fit bottom concave washer -9-  with the groove downwards facing the snap ring -10-  . Ensure that the snap ring -10-  and concave washer -9-  are seated correctly.

   Fig 1: Identifying Snap Ring Position

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   SNAP RING POSITION: PASM CHASSIS (HEIGHT -10 MM UNLIKE SERIES C2/C4)
   
   

   Vehicle version and equipment	Equipment (transmission)	Snap ring in position
   C2/C2S/C4/C4S Coupe  Rest of the World/USA and Targa  Rest of the World/USA	Manual transmission Tiptronic	Groove A Groove B
   C2/C2S/C4/C4S Cabriolet  Rest of the World/USA	Manual transmission Tiptronic	Groove B Groove A
   911 Turbo Coupe  Rest of the World/USA	Manual transmission and Tiptronic	Groove A
   911 Turbo Cabriolet  Rest of the World/USA	Manual transmission and Tiptronic	Groove B

   SNAP RING POSITION: STANDARD CHASSIS (SERIES C2 / C4 / C4 TARGA)
   
   

   Vehicle version	Equipment (transmission)	Snap ring in position
   C2/C4 Coupe  Rest of the World/USA and Targa  Rest of the World/USA	Manual transmission Tiptronic	Groove A Groove B
   C2 Cabriolet  Rest of the World	Manual transmission Tiptronic	Groove B Groove A
   C2 Cabriolet  USA	Manual transmission and Tiptronic	Groove A
   C4 Cabriolet  Rest of the World/USA	Manual transmission Tiptronic	Groove B Groove A

   SNAP RING POSITION: PERFORMANCE CHASSIS (I 030 / HEIGHT -20 MM UNLIKE SERIES C2/C4)
   
   

   Vehicle version	Equipment (transmission)	Snap ring in position
   C2/C2S/C4/C4S Coupe  Rest of the World	Manual transmission	Groove A

3. Place pre-tensioned coil spring (with the tighter end of the spring) on the vibration damper.
4. Slide the bellows/additional spring assembly onto the piston rod.
5. Fit washer.
6. Position spring strut mount -2-  onto the piston rod (with supporting mount -2-  , compensating part -3-  and spring support -4-  assembly in correct position).

   Place the lug on the spring strut mount in the groove of the piston rod (twist lock of piston rod opposite the supporting mount).

   Fig 2: Supporting Mount Assembly

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7. Fit new lock nuts on the piston rod. Place the end of the coil spring on the concave washer stop -arrow-  .
   Fig 3: Locating Coil Spring

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8. Align the spring strut mount with the vibration damper. -cast-on section-  of spring strut mount must line up with the middle fork of the lower vibration damper.
   Fig 4: Positioning Spring Strut Mount

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9. Tighten lock nut to 32 Nm (24 ftlb.). Counter at the bolts (M8) on the spring strut mount at the same time.

   There is no need to counter at the piston rod because there is a strong grip between the spring strut mount and piston rod.

   On PASM spring struts, use a suitable socket wrench insert, e.g. socket wrench insert for ATF temp. switch assembly NR.18  .

   Tightening torque for all 997 rear-axle spring struts: 32 Nm (24 ftlb.).

   The tightening torque of 32 Nm (24 ftlb.) applies - even contrary to previously published specifications - for all 997 rear-axle spring struts (conventional and with PASM)!

   Fig 5: Tightening Bolt On Spring Strut Mount

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