Suspension Control ( Automatic - Electronic ): Service and Repair
Dynamic Ride Control, Emptying and Filling
• Extracting, evacuating and filling the whole DRC line (lines/damper and central valve) is performed with the Filling Device for DRC System (VAS 6544). Depending on the DRC system equipment in the dealership, the equipment may need to modified or updated to match Filling Device for DRC System (VAS 6544). The following choices are possible:
Special tools, testers and auxiliary items required
• Upgrade Kit, Filling Device for DRC System (VAS 6209/4 )
• The Upgrade Kit, Filling Device For DRC System ( VAS 6209/4) serves as an upgrade to the Charging Device For DRC System (VAS 6209) already found in dealerships.
• Retrofit Kit, DRC System (VAS 6209/5)
• The Retrofit Kit, DRC System (VAS 6209/5) is needed if the dealership has the Pressure Pump (VAS 6209/3 ) and wants to upgrade the Filling Device For DRC System (VAS 6544). The Supplement Set, DRC System (VAS 6209/6) is also necessary.
• Supplement Set, DRC System (VAS 6209/6)
• The Supplement Set, DRC System (VAS 6209/6) is needed up upgrade the already available Pressure Pump (VAS 6209/3) in the Filling Device for DRC System (VAS 6544). The requirement is that the dealership already have the Charging Device for DRC System (VAS 6209). If the dealership does have the Charging Device for DRC System (VAS 6209), then the Retrofit Kit, DRC System (VAS 6209/5) must be obtained.
• Charging Device for DRC System (VAS 6544)
• Updating the equipment for the DRC system must be done one time only. It is not necessary to convert back again. The procedure for draining and filling the complete DRC system is described using the Filling Device for DRC System (V.A.S 6544).
Only approved oil for filling and draining must be used. For this, observe.
As a replacement part, shock absorbers and lines are delivered empty.
Filling must only be performed at ambient temperature of approximately 20 °C.
Lines/dampers and central valves may only be suctioned, evacuated and filled when they are installed and connected.
• The line shut-off valve must remain open when extracting, evacuating and filling the DRC system (lines/damper and central valve).
While filling the DRC system, the gas reservoir to the pressure clamps is checked for leaks on the piston on the inside of the central valve.
CAUTION!
Always wear safety goggles!
Valves of filling device are open when ratchet levers are parallel to direction of flow.
Lines must not be bent.
Required equipment
1 Front shock absorber adapter
• Not for this model
2 Rear shock absorber adapter
• Not for this model
3 Fill lines with quick-release fastener
4 Venturi injector with exhaust hose
• From the Charging Device for DRC System (VAS 6209 )
5 Connecting hose
• From the Charging Device for DRC System (VAS 6209 )
6 Charging Device for DRC System (VAS 6544)
7 Container for used oil
• Empty before starting the work
• Identification: Red dot
• Before filling the DRC system, make sure the oil reservoir for the Charging Device for DRC System (VAS 6544) and the line between the pressure pump and oil reservoir are filled with oil.
• The old oil reservoir from the Charging Device for DRC System (VAS 6544) must be empty.
Drain old oil reservoir.
- Remove cap - arrow - from the old oil reservoir - 1 - and drain the old oil.
- Install the cap - arrow - on the old oil reservoir - 1 -.
Fill and bleed the Charging Device for DRC System (VAS 6544).
- Fill the oil reservoir - 2 - with new oil up to the marking and position the O-ring to the height of the oil level.
- Close the shut-off valve - A - and - C - on the Charging Device for DRC System (VAS 6544).
- Close needle valve - B -.
- Connect hose - 2 - to the old oil reservoir - arrow - and to the quick-release fastener - 4 - on the Charging Device for DRC System (VAS 6544).
- Connect the Venturi injector - 3 - and vent hose to the old oil reservoir - arrow - as illustrated.
- Connect the compressed air to the Venturi injector - 3 -.
- Open the locking valve - C -.
- Open locking valve - A - briefly, for approximately 1-2 seconds, until the connecting line - 1 - between the oil reservoir - 2 - and pressure pump is filled and does not contain bubbles.
- Close locking valve - C -. Remove the compressed air connector form the Venturi injector.
Suctioning
CAUTION!
Always wear safety goggles!
- Turn the front wheel on the side to be suctioned toward the outside.
- Remove the dust cap from the front suction/fill valve.
- Connect the fill line and quick-release fastening - 1 - from the Charging Device for DRC System (VAS 6544) => [ (Item 3) Fill lines with quick-release fastener ] to the front suction/fill valve on the line to be suctioned.
- Remove rear wheel on the side of the line to be suctioned.
- Free up wheel housing liner for the rear suction/fill valve.
- Remove dust cap from the rear suction/fill valve.
- Connect fill line and quick-release fastening - 1 - from the Charging Device for DRC System (VAS 6544) => [ (Item 3) Fill lines with quick-release fastener ] to the rear suction/fill valve on the line to be suctioned.
- Connect the fill lines => [ (Item 3) Fill lines with quick-release fastener ] to the connections - A - and - B - on the Charging Device for DRC System (VAS 6544).
Shut-off valve - A - and - C - on the Charging Device for DRC System (VAS 6544) closed.
Needle valve - B - closed.
Hose connected - 2 - to the old oil reservoir - arrow - and to the Charging Device for DRC System ( VAS 6544) - 4 -.
Venturi injector - 3 - connected to the old oil reservoir vent hose - arrow - on the Charging Device for DRC System (VAS 6544).
Compressed air to the Venturi injector - 3 - connected.
- Open valve - C - until the last of the oil is extracted from the DRC system. (Visible on the return hose - 2 - to the used oil reservoir).
- When the pressure manometer shows approximately minus 0.9 bar, close the valve - C - and disconnect the compressed air hose from the Venturi injectors.
• Check for leaks.
• Vacuum must be stable for at least 2 minutes at minus 0.9 bar.
- Check the oil level on the oil reservoir, fill with new oil up to the marking if necessary and position the O-ring to the height of the oil level.
- Open the needle valve - B - approximately 2 turns and let the oil run out of the oil reservoir on the Charging Device for DRC System (VAS 6544) into the evacuated DRC system.
Oil flows from the reservoir into the connected DRC system. This is shown by the decreasing oil level in the oil reservoir. Depending on the amount of oil remaining, the procedure may take several minutes. As the system fills up, the oil level goes down slower. If the level of the oil no longer moves, the first step of the filling process is complete.
- Close needle valve - B -.
- Open valve - A - and fill the DRC system to 22 bar by pumping the lever on the hand pump - 1 - several times.
• While filling, make sure the oil reservoir on the Filling Device for the DRC System (VAS 6544) does not run dry; fill with reservoir with new oil if necessary.
• When a pressure of 22 bar is reached, close the valve - A - and do not pump the hand pump lever any more.
• If the pressure does not reach 22 bar or if it continually drops, check all connections for damage or leaks. If no issues are found on the outside, the gas reservoir to the pressure clamps on the piston on the inside of the central valve is leaking. Replace the central valve.
- Open the needle valve - B - slightly and let the pressure drop to 16 bar.
• Close the valve - B - when the indicator on the pressure manometer reaches the 16 bar marking.
DRC system is filled.
- Disconnect the fill line and quick-release fastener on the Filling Device for the DRC System (VAS 6544) => [ (Item 3) Fill lines with quick-release fastener ] from the rear and front suction/fill valve.
- After filling, check the pressure on each DRC line. Refer to => [ Dynamic Ride Control, Checking System Pressure ] Dynamic Ride Control, Checking System Pressure.
- Mount rear wheel.
- Install dust cap on the rear and front suction/fill valve.