Air Spring Damper
Air Spring Damper
Special tools, testers and auxiliary items required
• Torque wrench (5-50 Nm) (VAG 1331)
• Torque wrench (40-200 Nm) (VAG 1332)
• Torque wrench (5-60 Nm) (VAG 1783)
• Open end spanner insert AF 10 (V.A.G 1783/1)
• Pliers (T40067)
• Wood block (hardwood) 30 x 50 x 1,000 mm
Removing
The air spring damper is removed together with the mounting bracket and upper control arms.
During assembly, make sure no pressure points form on the air spring damper boot.
Air spring damper, disassembling and assembling. Refer to => [ Air Spring Damper ] Front Suspension.
- Place the vehicle on a hoist. Refer to => [ Positioning Vehicle on the Hoist and on its Wheels ] Positioning Vehicle on the Hoist and on its Wheels.
- Remove the wheel covers, remove the cover cap on light alloy wheels (removal hook in vehicle tool kit).
- Remove the wheel.
- Secure the brake disc with a wheel bolt.
- Clean the air spring damper air connection area.
- Remove the connecting piece - 1 - from the residual pressure valve - 2 -. Air then escapes.
• Generally, the residual pressure valve - 2 - must not be loosened or removed.
- Seal both connections. Make sure that no dust particles enter the connections.
- Loosen the quick release fasteners - 1 and 2 - and remove the noise insulation.
- Remove the drive axle from the transmission flange.
- Remove the nut - 1 -, bolt - 2 - and both control arms - 3 - upward.
• Do not widen the slits in the wheel bearing housing using a chisel or similar tool.
- Remove the coupling rod for the level control system sensor - 1 - from the track control arm.
- Remove the left and right connecting links - 2 -. Refer to => [ Connecting Link ] Front Suspension.
- Remove the air spring damper bolt - 3 - from the control arm, by pulling it outward.
- Loosen the stabilizer bar bolts evenly 5 turns.
- Remove the plenum chamber cover.
- Unclip and disconnect the electrical connector - 4 -.
- Remove the bolts - 1 through 3 -.
- Working from the wheel housing side outward, press the mounting bracket out of the body bushings in the area with the threaded connections.
- Turn the steering gear to the left or right as far as the lock (for the removal of the left or right air spring damper).
- Press the control arm - 1 - down using a wood block - arrow A - far enough so the air spring damper - 2 - can be removed forward - arrow B -. A second technician is needed for this.
• When removing the air spring damper, make sure the protective sleeves on the steering, drive axle and air spring damper are not damaged.
- Remove the mounting bracket from the air spring damper. Refer to => [ Mounting Bracket ] Front Suspension.
If the air spring damper will be replaced, note the information found here. Refer to=> [ Air Spring Damper, Filling ] Air Spring Damper, Filling.
Installing
Installation is performed in the reverse order of removal. Observe the following when doing so:
During assembly, make sure no pressure points form on the air spring damper boot.
- Tighten the bolts/nuts for the components with bonded rubber bushings by hand. Raise the wheel bearing housing to tighten the bolts/nuts. Refer to => [ Wheel Bearing Housing, Raising to Control Position to Tighten Bolts ] Front Suspension.
- Install the mounting bracket to the air spring damper. Refer to => [ Mounting Bracket ] Front Suspension.
- Install the air spring damper to the body.
Tightening Sequence
- Tighten the bolts - 1 through 3 - by hand.
The mounting bracket guides must sit in the body bushings.
- Tighten the bolt - 2 -, then the bolts - 1 and 3 -. Refer to - item 3 - in => [ Mounting Bracket, Upper Control Arms and Air Spring Damper Assembly Overview ] Mounting Bracket, Upper Control Arms and Air Spring Damper Assembly Overview.
- Install the studs of the upper control arms - 2 - into the wheel bearing housing - 3 - and compress them as far as possible using the (T40067).
- Install and tighten the bolt - 1 -. Refer to - items 11 or 12 - depending on the version, in => [ Mounting Bracket, Upper Control Arms and Air Spring Damper Assembly Overview ] Mounting Bracket, Upper Control Arms and Air Spring Damper Assembly Overview
- Install the vehicle level control system sensor coupling rod - 1 - to the control arm. Refer to - item 9 - in => [ Subframe, Engine Carrier and Stabilizer Bar Assembly Overview ] Subframe, Engine Carrier and Stabilizer Bar Assembly Overview.
- Install the left and right couplings rods - 2 -. Refer to - items 15 and 16 - in => [ Mounting Bracket, Upper Control Arms and Air Spring Damper Assembly Overview ] Mounting Bracket, Upper Control Arms and Air Spring Damper Assembly Overview.
- Install and tighten the bolt - 3 - for the air spring damper to the control arm. Refer to - item 19 - in => [ Mounting Bracket, Upper Control Arms and Air Spring Damper Assembly Overview ] Mounting Bracket, Upper Control Arms and Air Spring Damper Assembly Overview.
- Tighten the stabilizer bar bracket bolts. Refer to - item 20 - in => [ Subframe, Engine Carrier and Stabilizer Bar Assembly Overview ] Subframe, Engine Carrier and Stabilizer Bar Assembly Overview.
- Connect the connecting piece - 1 - to residual pressure valve - 2 -. Refer to - item 23 - in => [ Mounting Bracket, Upper Control Arms and Air Spring Damper Assembly Overview ] Mounting Bracket, Upper Control Arms and Air Spring Damper Assembly Overview.
- Mount the wheel and tighten.
- Fill the air suspension system. Refer to => [ System Venting or Filling ] Level Control System.
- Readapt the control position. Refer to => [ Control Position, Programming ] Level Control System.
- Install the plenum chamber cover.