Front Suspension Strut, Removing and Installing (Allroad)

Front suspension strut, removing and installing (Allroad)
Removing
^ Perform system venting of suspension strut
^ Deactivate level control system
^ Remove wheels.
^ Secure brake disc using a wheel bolt.
^ Remove cover plenum chamber / battery

Note: In order not to damage joints of lower control arms, it is necessary to use engine/transmission jack VAG1383-A, for example, to brace against too strong rebound.

^ Loosen connection of air hose at suspension strut only far enough, so that air escapes.





^ After pressure in suspension strut/ air hose has completely escaped, remove air hose by loosening threaded connection at suspension strut.
^ Remove level sensor at track control link

Note installation position

Note: Observe level control system / automatic vertical headlight aim control refer to Vehicle Level Sensor.





^ Remove bolts -2-
Tightening torque: 45 Nm and then tighten another 55°.





^ Remove bolt (arrow)
Tightening torque: 45 Nm and then tighten another 55°.





^ Protect steering gear boot from damage.
Figure shows steering gear disassembled, to illustrate it more clearly.
If you wish to order protective sleeve -1-, its part number is 893 512 137.
^ Protective sleeve -1- must have a strip having dimension -A- from 20 to 25 mm cut out of it.
^ Carefully deburr cut edges.
^ Push protective sleeve over steering gear boot.
The open, slit should face downward.





^ Unscrew nut -1-.
Slits in wheel bearing housing may not be widened with a chisel or similar tool'
^ Remove hex bolt and lift out control arm -2-.
^ Swing away wheel bearing housing toward side, in direction of (arrow).
Bolts -3- and -4- may not be loosened!
Otherwise axle adjustment must be checked!
To unscrew hex bolt from suspension strut/track control link, you must detach guide link from wheel bearing housing.

Note:
^ Protect CV boot from damage, e.g.: place a leather cloth in between.
^ For safety reasons, put collar nut back on joint bolt of track control link with about 4 turns, so that it is flush.
^ Be sure that both lever arms are parallel to each other during greatest applied pressure, adjust if necessary.

Use 4 mm socket wrench to hold joint bolt if necessary.





^ Unscrew nut from joint bolt of guide link, then press off joint bolt.
Be careful not to damage CV boot in the process!





^ Unscrew bolt -2-, suspension strut/track control link.
^ Pull suspension strut down and out.





^ Only hold suspension strut at mounting bracket and at strut tube as shown in illustration.

Note: Be careful not to damage CV boot when removing suspension strut

^ Mark position of shock absorber - mounting bracket

Installing
Only hold suspension strut at mounting bracket and at strut tube.
^ Position mounting bracket according to mark.





^ Secure suspension strut to chassis using mounting bracket.
Use new bolts.
Bolt tightening sequence, as numbered in illustration, is mandatory.
Tightening torque: 45 Nm and then tighten another 55°
Always use new mounting bracket!
^ Bolt suspension strut together with track control link.
Tightening torque: 90 Nm
^ Bonded rubber bushings can only be turned to a limited extent The suspension strut1track control link bolt connection should therefore only be tightened when the vehicle is standing on the ground.

Note: Charge system before vehicle is allowed to stand on its wheels.

Note: Remove any adhesive remaining on thread of joint bolt.

^ Tighten new nuts to 100 Nm.
Use 4 mm socket wrench to hold joint bolt if necessary.





^ Insert upper control arm in wheel bearing housing and tighten new nuts -6- to 40 Nm.
^ Press upper control arm down as far as possible when tightening!
^ Secure Voss air connection. 2 Nm
^ Position chafe protection -7- properly.
^ Screw on new bolts for suspension strut and tighten to 20 Nm.
Be careful not to damage surface of brake lines!
^ Secure bracket for level control at track control link
^ Put rubber grommets in plenum chamber.

Note: System must be filled before vehicle rests on wheels!

^ Mount wheel and tighten to 120 Nm.
Observe assembly notes
^ Perform basic setting of level control