Operation CHARM: Car repair manuals for everyone.

Rear Suspension






Air Spring Damper

=> [ Air Spring Damper, Filling ]

Special tools, testers and auxiliary items required

Torque wrench (5-50 Nm) (VAG 1331)

Torque wrench (40-200 Nm) (VAG 1332)

Engine and transmission jack (VAG 1383A)

Torque wrench (5-60 Nm) (VAG 1783)

Wheel hub support (T10149)

Open end spanner insert AF 10 (VAG 1783/1)

Wood block (hardwood) 30 x 50 x 1,000 mm

Removing

- 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.

During disassembly, make sure no pressure points form on the air spring damper boot.

- 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.

- Remove the wheel housing liner.

- Clean the air spring damper air connection area.

- Disconnect 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.

- Remove the bolt - 1 - for the level control system sensor.





- Remove the nut - 3 -.

- Push the wheel bearing housing down by hand and remove the bolt - 4 - from the air spring damper/ track control arm.

- Insert a wood block in the subframe - arrow 1 - and support on the wheel bearing housing - arrow 2 -.





- Press the wheel bearing down using the wood block - arrow 3 - until the air spring damper - arrow 4 - can be removed toward the rear.

A second technician is needed to pull the air spring damper fork back.

- Place a folded cloth between the air spring damper and the track control arm.

- Release the wheel bearing housing slowly. Do not place the air spring damper - 1 - on the parking brake housing - 3 - or stabilizer bar - 2 - when doing so.





Right Air Spring Damper

- Remove the ventilation hose connection - 4 - from the filler neck.





Continuation for Both Sides

- Disconnect connector - 3 -.





- Remove the nut - 4 - and bolt - 5 -.

- Remove the bolts - 6 - (quantity: 3) and the air spring damper.

If the air spring damper will be replaced, note the information found here, refer to => [ Air Spring Damper, Filling ].

Installing

Installation is performed in the reverse order of removal. Observe the following when doing so:

When installing, make sure the boot is not damaged and there are no pressure points.

- Insert the air spring damper and tighten the bolts - 6 - (quantity: 3). Refer to - item 34 - in => [ Air Spring Damper, Wheel Bearing Housing and Wheel Hub and Bearing Assembly Overview ] Rear Suspension.





- Tighten the bolt - 5 -. Refer to - item 39 - in => [ Air Spring Damper, Wheel Bearing Housing and Wheel Hub and Bearing Assembly Overview ] Rear Suspension.

- Tighten the nut - 4 -. Refer to - item 33 - in => [ Air Spring Damper, Wheel Bearing Housing and Wheel Hub and Bearing Assembly Overview ] Rear Suspension.

- Connect the connector - 3 -.

- Tighten the connecting piece - 1 - to the residual pressure retaining valve - 2 -. Refer to - item 37 - in => [ Air Spring Damper, Wheel Bearing Housing and Wheel Hub and Bearing Assembly Overview ] Rear Suspension.

Right Air Spring Damper

- Install the ventilation hose connection - 4 - to the filler neck.





Continuation for Both Sides

- Install the level control system sensor bolt - 1 -. Refer to - item 35 - in.=> [ Stabilizer Bar, Track Control Arm, Tie Rod, Coupling Rod, Connecting Link, Trailing Arm and Level Control System Sensor Assembly Overview ] Stabilizer Bar, Track Control Arm, Tie Rod, Coupling Rod, Connecting Link, Trailing Arm and Level Control System Sensor Assembl. The sensor lever must face inward.





- Push the wheel bearing housing down by hand and install the bolt - 4 - for the air spring damper/track control arm.

- Only tighten the nut - 3 - by hand.

The bolt - 4 - cannot be tightening in the control position. The vehicle must be resting on its wheels.

- Install the wheel housing liner.

- Install the wheel and tighten.

- Place the vehicle on its wheels. Refer to => [ Positioning Vehicle on the Hoist and on its Wheels ] Positioning Vehicle on the Hoist and on its Wheels.

- Tighten the bolt - 4 - with the vehicle at the "standard level" and resting on the floor. Refer to - item 30 - in => [ Air Spring Damper, Wheel Bearing Housing and Wheel Hub and Bearing Assembly Overview ] Rear Suspension. Counter hold the nut - 3 - when doing this.

- Readapt the control position. Refer to => [ Control Position, Programming ] Level Control System.

Air Spring Damper, Filling

Special tools, testers and auxiliary items required

Adapter (T10157)

Air suspension strut charger (VAS 6231)

Steel gas bottle filled with argon or corgon

Air spring dampers are supplied as replacement parts with a minimum pressure. By sitting in storage for extended periods this pressure can diminish (just like a tire). This minimum pressure must be checked and if necessary restored by recharging before the air spring damper is removed from the packaging. If the air spring damper is removed from the packaging without this checking/recharging, this may cause indentations or kinks to form in the dust boot before it reaches its normal shape. These indentations lead to preliminary damage and may lead to premature failure.

- Remove the cover from the packaging.

- Remove the union bolt - arrow - from the residual pressure holding valve.





- Close the valve on the steel gas bottle.

- Become familiar with the relevant rules for the prevention of accidents for pressurized containers and technical gases.

- Connect the (VAS 6231) and the (T10157) as shown in the illustration.





1. Air spring damper in packaging

2. Steel gas bottle for argon, corgon with gauges

3. (VAS 6231)

4. (T10157)

The air spring damper can only be filled with the gases listed so that no "unfiltered" air can get into the air suspension system.

- Set the flow rate limiter gauge to 2.0 L/min - arrow -.





- Now fill the air spring damper using several individual pressure bursts.

The display only shows a correct pressure if the back pressure of the residual pressure retaining valve is overcome. The back pressure is at approximately 3.5 bar. The air spring damper is filled with enough gas when the pressure reaches 3.5 to 4.5 bar.





- Make sure the pressure does not exceed 4.5 bar when filling.

- Disconnect the (VAS 6231) from the (T10157), gas escapes at pressure above 3.5 bar.

Minimum pressure is now reestablished. You can remove the air spring damper from the packaging.

- After installation, first drive the vehicle at a high ride height and then at the normal ride height. Repeat this sequence once more.

By moving the ride height settings twice, the majority of the gas is exchanged with filtered air from the air supply motor.

- Install the air spring damper.