Air Spring Shock Absorber
Air Spring Shock Absorber
• Observe the information regarding air spring shock absorber repair. Refer to => [ Air Spring Damper Repair Information ] Air Spring Damper Repair Information
Special tools, testers and auxiliary items required
• Special Socket Wrench 21 mm (3186)
• Torque Wrench (V.A.G 1332)
• Release Tool Set (VAS 1978/35)
• Spring Compressor (V.A.G 1752/1)
• Spring Holder (V.A.G 1752/3A)
• Spring Holder (V.A.G 1752/7)
• Disassembly Wedge (3409)
• Vehicle Diagnostic Tester (VAS 5051B)
Perform the Following Work
- Remove the air spring damper. Refer to => [ Air Spring Damper ] Air Spring Damper.
• Check whether the air spring is still filled with a residual pressure of 3 bar.
• Press with the thumbs on the air spring bead. Bead must demonstrate noticeable resistance.
• If significant resistance is not noticed, the air spring is not pressurized.
Disassembly
- Clamp the air spring shock absorber at the stabilizer bar mount in a vise using protective covers.
A Aluminum protective covers
Make sure that the mount is not damaged.
- Eject the cable sockets from the air spring shock absorber connector with the (VAS 1978/35).
- Unscrew the bolts - 2 - and remove the cover - 3 -.
- Conduct the cable through the grommet - 1 -.
- Unscrew the nut from the mount while counterholding at the hex fitting - 3 -.
1. Commercially available ratchet
2. (3186)
- Remove the mount from the shock absorber.
- Push the boot down.
- Press the air spring rolling piston - 1 - off the shock absorber using the (V.A.G 1752/1).
• To prevent damage, insert a rubber mat - 6 - or similar protection between the (V.A.G 1752/7) - 5 - and the rolling piston.
1. Rolling piston
2. Outer guide
3. (V.A.G 1752/1)
4. (V.A.G 1752/3A)
5. (V.A.G 1752/7)
6. Rubber mat or similar item
• Insert protective material such as rubber between the (V.A.G 1752/7) and rolling piston.
• Insert protective material such as rubber between the (V.A.G 1752/3A) and shock absorber.
• Make sure that the rolling piston - 1 - does not slip down out of the outer guide - 2 -.
• If air spring is reused and air spring has slipped out of outer guide, it must be slid in again by forming even circumferential folds on the rolling bellows - arrows -.
- Pull the boot - 1 - off of the shock absorber - arrow -.
Assembly
- If the shock absorber was not replaced, the sealing rings - arrows - at the piston rod and the shock absorber tube must be replaced.
- Clean the contact surface with a lint-free cloth.
• Even the smallest amount of contamination leads to air spring shock absorber leaks.
- Lightly lubricate the sealing rings with (N 052 150 00).
- Slide the anti-extraction device onto the shock absorber tube.
- Install the boot - 1 - on the shock absorber.
- Engage the boot groove at the shock absorber - arrow -.
• If air spring is reused and air spring has slipped out of outer guide, it must be slid in again by forming even circumferential folds on the rolling bellows - arrows -.
- Extend the shock absorber line, e.g. with a cable, so that it can be routed through the air spring.
- Push the boot down.
- Ensure that the buffer stop - 1 - is seated properly in the cover - 2 - - arrow -.
• The large diameter of the buffer stop - 1 - must clamp in the cover - 2 -.
- Install the mount and secure it with a new nut while counterholding at the hex fitting - 3 -.
1. Commercially available ratchet
2. (3186)
- Align the air spring so that the pressure-holding valve - 1 - is located exactly on the imaginary symmetrical axis - arrow - of the air spring shock absorber.
- The pressure-holding valve - 1 - points toward the hole for the coupling rod - 2 -.
• During alignment, only rotate at the rolling piston in order to avoid damaging the rolling bellows inside the air spring.
- Install the cover - 3 - and secure with the bolts - 2 -.
Vehicles with Non-Bonded Grommet
- Insert the grommet - 1 - in the cover - 3 -.
Continuation for Both Variants
- Conduct the cable through the grommet.
- Insert the cable socket in the connector housing.
- Install the air springs but do not connect the air line yet. Refer to => [ Air Spring Damper ] Air Spring Damper.
- Using the (V.A.G 1383 A) , raise the air spring shock absorber until the piston - 1 - is lying on the anti-extraction device - arrow -.
- Press the anti-extraction device into the piston using the (3409).
1. (3409)
- Continue lifting the air spring shock absorber using the (V.A.G 1383 A) until the welded ring on the shock absorber tube is approximately 3 mm inside the extraction piston - arrow -.
- When draining, hold the pressure retaining open by opening the valve plunger with a 5 mm hex wrench so that the air can flow through.
• This will prevent the dust boot from creasing.
- Slide the boot onto the air spring.
The air line has 2 markings.
Insert the air line until the front marking - arrow A - is completely covered by the union nut.
Only the second marking - arrow B - may still be visible on the air line.
- Install the wheel and tighten the wheel bolts. Refer to => [ Wheel Bolt Torque Specification ] [1][2]Specifications.
- Fill the air spring shock absorber using the (VAS 5051B).
Tightening Specifications
