Air Line, Servicing
Pneumatic Level Control System
Air Line, Servicing
Special tools, testers and auxiliary items required
• Torque wrench (5-60 Nm) (VAG 1783)
• Open end spanner insert AF 10 (VAG 1783/1)
• Air hose pliers (VAS 6228)
If the air line is damaged, the damaged area can be replaced.
If the connection leaks, the air line can be shortened by 10 mm and a new connecting piece installed. Refer to => [ Connector Piece, Replacing ]. Connector Piece, Replacing
• The air line between the air supply unit and the solenoid valve block is replaced completely with an original line. Note different versions. Route the air line between the air supply unit and the solenoid valve block parallel to the wiring harness.
• The air line between the left front air spring damper and the solenoid valve block is replaced completely with an original line. Route the air line between the air supply unit and the solenoid valve block parallel to the wiring harness.
• The air line between the solenoid valve block and the right front air spring damper is only replaced with an original line in the right wheel housing. Shorten the original line as needed. On the left side, the line is replaced with parts from the repair kit.
• Damaged air lines in the interior are replaced completely with an original line. Route the new air line along the air line/wiring harness. Secure the new air line at the locations marked. Replace cut cable ties if necessary.
• Before disconnecting an air line connection, clean the connection area.
• Contaminants entering the lines can lead to system malfunction.
- Clean the connector piece area and corresponding separation point.
- Cut through the air line at a right angle at the connector area using air hose pliers (VAS 6228).
- Remove the connector piece and air line.
- Then mark ends of the air line in the vehicle and both ends of new air line with a waterproof pen.
With 17 mm or 22 mm markings, check whether the connector piece is inserted far enough in the air line.
- Place foam rubber on both lines.
- Install the new line connector.
• Connector pieces in the line connector are already tightened to proper torque. Air lines only have to be connected.
- Remove the transport protection cap.
- Slide the old air line through gaskets - 1 and 2 -.
- Then slide the air line with some force through edges - 3 and 4 - of cutting rings as far as the stop - 5 - in the line connector.
- Slide the foam rubber onto the connector piece.
- Repeat the procedure with new air line.
- Connecting piece replacing, refer to => [ Connector Piece, Replacing ]. Connector Piece, Replacing
Connection Area Overview
Right Front Air Spring Damper Separation Point in the Right Wheel Housing
1. Air line (shortened new original line)
2. Foam rubber, 10-15 mm long
3. Line connector
4. Plug socket cable tie, for line connectors to the wiring harness
• In this area, the original line must be used as a replacement because only the original line has the foam rubber protector. Also, the original line has a very narrow radius in the area where it connects to the air spring damper. This narrow radius cannot be created on the air line from the repair set.
- Secure the line connector - 3 - on the plug socket - 4 - using a new cable tie as shown in the illustration.
Right Front Air Spring Damper Separation Point in the Left Wheel Housing
1. Air line
2. Plug socket cable tie
3. Foam rubber, 10-15 mm long
4. Line connector
5. Cable tie, for the line connector to the wiring harness
- Install the new air line - 1 - in the plug socket using a new cable tie - 2 -.
- Secure the line connector - 4 - on the wiring harness using a cable tie - 5 - as shown in the illustration.
Separation Points Near the Solenoid Valve Block for the Air Lines Routed to the Back
• The illustration shows all three line connectors for the air lines routed through the interior.
- Secure one, two or three air lines as needed to each other and on the existing air lines using cable ties - arrow B - as shown in the illustration.
- Install the air lines in the line bracket - arrow A -.
Right Rear Air Spring Damper Separation Point
1. Air line
2. Foam rubber, 10-15 mm long
3. Line connector
4. Cable tie, for the line connector to the wiring harness
5. Cable tie
- Secure the line connector - 3 - to the wiring harness - arrow A - and - arrow B - with the cable tie - 4 -.
Separation Point for the Left Rear Air Spring Damper and Pressure Reservoir
• The illustration shows both line connectors for the left rear air lines.
1. Purple air line (shortened new original line), for the pressure reservoir
2. Black air line, for the left rear air spring damper
3. Foam rubber, 10-15 mm long
4. Cable tie, for the line connector to the wiring harness
5. Line connector, for the black air line
6. Cable tie
7. Line connector, for the purple air line
• The original line must be used as a replacement for the purple air line because only the original line has the foam rubber protector.
- Secure one or two of the line connectors - 5 - and - 7 - as needed on the wiring harnesses - arrow A -, - arrow B - and - arrow C - using a cable tie - 4 - as shown in the illustration.
Tightening Specifications