Dynamic Ride Control (DRC II), Emptying and Filling
Dynamic Ride Control (DRC II), emptying and filling
Special tools, testers and auxiliary items required
^ Charging device V.A.S 6209
^ Vehicle connection adapter V.A.S 6209/1
Only approved oil should be used for filling or topping off.
Filling must only be done at room temperature (approx. 20 degrees Celsius).
Vehicle must never be placed on wheels with closed, filled system and locked central valves. This inevitably leads to leaks and system malfunction.
Equipment valves are open when locking levers are longitudinal to direction of flow.
Workshop equipment needed
1 - Vehicle connection adapter with ventilation valve V.A.S 6209/1
2 - Connecting hose
3 - Venturi with exhaust hose
4 - Valve
5 - Pressure reducer
6 - Pressure gauge with valves and filler hose
7 - Intake hose
8 - Used oil container
Identification: red dot
9 - New oil container
Identification: green dot
Fill new oil container
CAUTION!
Protective eye wear must be worn for all procedures!
- Connect suction hose - 7 - to new oil container - 9 -.
- Immerse free end of hose - 7 - in oil in storage container.
- Close valve - 4 -.
- Connect valve - 4 - to new oil container.
- Connect venturi - 3 - to valve - 4 -.
- Connect compressed air hose to venturi - 3 -.
- Slowly open valve - 4 - and draw oil out of storage container into new oil container.
Maximum quantity 1.5 liters.
Note:
^ Oil can foam up when it is drawn out.
^ Stop suction process so that foam can settle.
Empty used oil container
CAUTION!
Protective eye wear must be worn for all procedures!
- Place suitable container for collecting used oil near used oil container - 8 -.
- Connect connecting hose - 2 - to used oil container - 8 - and keep free end in collection container.
- Close valve - 4 - (lever perpendicular to direction of flow).
- Attach valve - 4 - to used oil container - 8 -.
- Connect pressure reducer - 5 - to valve - 4 -.
- Pull out rotary knob at pressure reducer - 5 - and turn left to stop.
- Connect compressed air connector to pressure reducer - 5 -.
- Adjust pressure to 0.1 bar.
- Slowly open valve - 4 - and press oil out of used oil container - 8 - as completely as possible.
- Close valve - 4 -.
- Turn pressure reducer - 5 - back to 0 bar.
Note:
^ A small quantity of remaining oil is permitted.
^ An empty used oil container is necessary for the next step, "evacuation"!
Suctioning oil from damper and line, evacuating and filling
Procedure is described for front axle, same procedure applies to rear axle.
CAUTION!
Protective eye wear must be worn for all procedures!
Note:
^ Fill new oil container ahead of time
^ Empty used oil container ahead of time
Suctioning:
- Remove plastic cover - 1 -.
Note:
^ To attach or detach adapter V.A.S 6209/1, system line must be locked at central valve to limit the quantity of oil leaked to a minimum and to prevent pressurized central valve from emptying.
^ Allocation of central valves and wiring harnesses
- Loosen lock nut - 1 - on line to be suctioned, screw in shut-off screw - 2 - until it is hand tight and lock nut - 1 - again.
- Connect adapter V.A.S 6209/1 to line to be suctioned.
- Secure pressure gauge - 6 - with chain to vehicle in an appropriate place and connect filler hose to new oil container - 9 -.
- Connect adapter V.A.S 6209/1, item - 1 - in illustration, to pressure gauge - 6 -.
- Connect connecting hose - 2 - to pressure gauge - 6 - and connect free end to used oil container - 8 -.
- Attach valve - 4 - to used oil container - 8 -, valve closed.
- Connect venturi - 3 - to valve - 4 -.
- Adjust valve as follows:
- A - = Open (lever longitudinal to direction of flow)
- B - = Closed (lever perpendicular to direction of flow)
- C - = Open (lever longitudinal to direction of flow)
- D - = Closed (lever perpendicular to direction of flow)
- Connect compressed air hose to venturi - 3 -.
- Slowly open valve - 4 - at used oil container completely.
Oil is suctioned.
- Open line connection - 1 - at strut approx. one turn and suction oil out until as little remains as possible.
- To shorten suction process, valve - D - should be quickly and regularly opened lightly and closed again immediately during the suction process.
- Perform suction procedure until there is no more oil in connecting hose - 2 -.
- Close line connection - 1 - to strut again.
Evacuating:
"Suctioning" step must be performed.
- Create a vacuum of at least -0.9 bar at pressure gauge - 6 -.
- Continue evacuation process at minimum -0.9 bar for at least 2 minutes.
- Bleed pressure gauge filler line - 6 -.
Note:
^ During the evacuation process, only open valve lightly - B - and allow oil to be suctioned without bubbles from new oil container - 9 - to pressure gauge.
- Close valve - C -.
- Close valve - 4 -.
- Disconnect compressed air line.
- Perform leak test.
Note:
^ Vacuum must remain stable at -0.9 bar for at least 2 minutes.
Filling
Note:
^ "Evacuating" step must be performed.
^ Vacuum must be created for "evacuating" step.
- Valve - A - is open.
- Valves - B - to - D - are closed.
- Connect compressed air connector to pressure reducer - 5 -.
- Close pressure reducer completely.
Display 0 bar
- Place pressure reducer - 5 - together with connected compressed air connection on new oil container - 9 -.
- Set pressure reducer to 2 bar.
- Valve - B - open.
Oil flows out of new oil container - 9 - into connected component. Recognizable with decreasing oil level in new oil container.
- Slowly increase pressure at pressure reducer - 5 - to 5 bar.
Note:
^ At this point, read pressure only at pressure gauge - 6 -, not at pressure reducer.
Component is filled.
- Close valve - A -.
- Close valve - B -.
- Close pressure reducer - 5 - (pull out rotary knob on pressure reducer - 5 - and turn it left to stop).
- Remove adapter V.A.S 6209/1 from vehicle.
- Loosen lock nut - 1 - on filled line, unscrew shut-off screw - 2 - until it is hand tight and lock nut - 1 - again.
- After filling process, perform pressure check on respective DRC line.