Assembling Rear 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 rear 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 rear axle of the Cayenne.  .
• 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  . → 4X00IN TIGHTENING TORQUES FOR REAR AXLE

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

1. Fit 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:
   Fig 1: Identifying Cap, Washer, Rubber Stop And Boot Assembly

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 1.1. Push 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 washer -2-  as described in Step  1.2 and cap -1-  into the boot -see Fig 2- and pull the lip carefully over the cap.
      Fig 2: Fitting Cap Into Boot

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Fit the lower concave washer and the lower support together at the correct position (not twisted). (Align triangular markings all the way around). → Fitting lower concave washer into lower support 
   Fig 3: Fitting Lower Concave Washer Into Lower Support

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Fit the upper concave washer -1-  and the upper support -2-  together at the correct position (Align triangular markings all the way around).
   Fig 4: Fitting Upper Concave Washer With Upper Support

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

   The color marking must be on the lower spring coils.

   Fig 5: Locating Coil Spring Stop In Lower Concave Washer

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Push the boot/rubber stop/washer, if necessary and cap assembly loosely onto the piston rod. If a washer is fitted (no longer used from model year B onwards), check that the washer is on the piston rod!
8. Fit the upper concave washer/upper support assembly.
   • Position the upper spring support precisely at the coil spring stop -arrow-  .
     Fig 6: Locating Upper Spring Support Stop On Coil Spring

     Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Position the concave support in such a way that the center lines -A-  and -B-  are parallel.
   Fig 7: Identifying Concave Support Assembly

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. Fit supporting mount and tighten 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.
       Fig 8: Aligning Concave Support On Right Spring Strut

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
12. Finally fit the lock nut using socket-wrench insert 3353  or for PASM, socket-wrench insert 3077  .

    Observe the specified tightening torque:

    Conventional spring strut: Tightening torque 60 Nm (44 ftlb.) +/-5 Nm (+/-3.5 ftlb.) 

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

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.
      Fig 9: Fitting Boot In Upper Spring Strut

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    • Push the boot down fully and pull the cap on the shock absorber down -arrow-  .
      Fig 10: Fitting Boot In Lower Spring Strut

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
14. Fit the cover (for PASM, check the position of the cable holder!) and secure with four nuts -1-  . Pressing force +26 Nm (+19 ftlb.) +/-1 Nm (+/-0.5 ftlb.) 
    Fig 11: Identifying Cover And Nuts

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
15. On vehicles with PASM, fit the grommets -1-  onto the cable by opening the grommets slightly using commercially available Seeger circlip pliers. This makes it easier to push pins through the grommets.
    Fig 12: Identifying Grommets

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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.

    Fig 13: Identifying Cable Guide Alignment

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.