Assembling Front Spring Strut

Information 

• The coil springs are only available in pairs (as a set). 
• The spring-strut mounts for the right and left sides are identical parts. 

1. Prepare components for assembly.
2. Assemble spring strut.
   1. 2.1. Insert additional spring -8-  at the correct position -arrow-  in the bellows -7-  .
      Fig 1: Fitting Spring And Bellows

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   2. 2.2. Fit stop washer -9-  and lower spring plate -10-  on the vibration damper -11-  .
      Fig 2: Assembling Spring Strut

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   3. 2.3. Place bellows -7-  with additional spring -8-  and coil spring -6-  on the vibration damper -11-  .

      Information 

      • Coil spring marking -1- comprising two different colored lines (e.g. one red and one white line) indicates the spring rate and spring length (depending on vehicle variant and equipment). 
      • A marking -2- comprising one colored line indicates the coil spring tolerance group (load group) and determines whether or not a tolerance compensation shim -arrows- will be installed. The colored line -2- is either YELLOW or BLUE. 
      • If you are installing new coil springs, then order two tolerance compensation shims at the same time. As coil springs of load group 1 or 2 will be supplied, you will then have the tolerance compensation shims for installation (if required). 
        Fig 3: Identifying Coil Spring Color Marking

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      • Yellow colored line -2- = do not use a tolerance compensation shim. Only relevant when replacing coil springs. Remove tolerance compensation shim that may be fitted as standard (installation permitted during production with borderline tolerance). Blue colored line -2- = use a tolerance compensation shim. 
        Fig 4: Locating Compensation Shim Tolerance

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3. Assemble spring-strut mount -2-  , ball bearing -3-  , tolerance compensation shim -4-  (if available or required/see INFORMATION ) and upper spring plate -5-  and fit them on the piston rod.
   Fig 5: Installing Spring-Strut Mount

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   Make sure that the coil spring is positioned correctly at the upper/lower spring plate -arrows-  .

   Fig 6: Positioning Coil Spring

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4. Tighten hexagon nut using socket-wrench insert 9630/2  or socket-wrench insert 3186  .

   When tightening the hexagon nut, counter at the piston rod using a suitable open-ended wrench or ring wrench.

   Tightening torque 70 Nm (52 ftlb.) 

5. Remove spring compressor and check once again that all components are positioned correctly.
6. On vehicles with PDCC, fit PDCC holder at the correct position.

   The lug on the PDCC holder must be inserted in the cut-out on the concave washer -arrow-  .

   Fit hexagon-head bolt.

   Tightening torque 46 Nm (34 ftlb.) 

   Fig 7: Positioning PDCC Holder

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