Air Spring Shock Absorber, Repairing: Notes

WARNING: This page is about a different car, the 2014 Volkswagen Touareg, 2013 Volkswagen Touareg, 2012 Volkswagen Touareg, and 2011 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Wrench - Strut Socket - 21mm:3186
Torque Wrench 1332 40-200 Nm :VAG1332
Release Tool Set:VAS1978/35
Spring Compressor Kit - Spring Tensioner:VAG1752/1
Spring Compressor Kit - Spring Retainer with Inserts:VAG1752/3A
Spring Compressor Kit - Spring Retainer w/Inserts:VAG1752/7
Trim Removal Wedge:3409

NOTE:

Observe the information regarding air spring shock absorber repair. Refer to AIR SPRING SHOCK ABSORBER, REPAIR INFORMATION .

-- Remove air spring shock absorber. Refer to AIR SPRING SHOCK ABSORBER, REMOVING AND INSTALLING .

NOTE:

Check whether the air spring is still filled with a Residual Pressure Of 3 Bar (43.5 Psi).

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To do so push the air spring bead with thumbs. The bead must demonstrate noticeable resistance.

If significant resistance is not noticed, the air spring is not pressurized.

Disassembling the Air Spring Shock Absorber

-- Clamp the air spring shock absorber at the stabilizer bar mount in a vise using protective covers.

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A - Aluminum protective covers

CAUTION:

Make Sure That The Mount Is Not Damaged.

-- Eject the cable sockets from the air spring shock absorber connector with the Release Tool Set:VAS1978/35 .

-- Remove the bolts -2- and the cover -3-.

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-- Conduct the cable through the grommet -1-.

-- Unscrew the nut from the mount while counter-holding at the hex fitting -3-

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Ratchet (commercially available)
Wrench - Strut Socket - 21mm: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 Spring Compressor Kit - Spring Tensioner:VAG1752/1 .

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NOTE:

To prevent damage, insert a rubber mat -6- or similar protection between the Spring Retainer for Audi A4:VAG1752/7 -5- and the rolling piston.

Rolling Piston
Outer Guide
Spring Compressor Kit - Spring Tensioner:VAG1752/1
Spring Compressor Kit - Spring Retainer with Inserts:VAG1752/3A
Spring Compressor Kit - Spring Retainer w/Inserts:VAG1752/7
Rubber mat or similar item

CAUTION:

Insert protective material such as rubber between the Spring Retainer for Audi A4:VAG1752/7 and rolling piston.
Insert protective material such as rubber between the Spring Compressor Kit - Spring Retainer w/Inserts:VAG1752/3A and the shock absorber.
Make sure that the rolling piston -1- does not slip down out of the outer guide -2-.

NOTE:

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 boot -arrows-.

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-- Pull the boot -1- off of the shock absorber -arrow-.

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Air Spring Shock Absorber, Assembling

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-- 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.

NOTE:

Even the smallest amount of contamination leads to air spring shock absorber leaks.

-- Lightly grease the seal with Lubricating Grease:G 052 150 A2 .

-- Slide the anti-extraction device onto the shock absorber tube.

-- Install the boot -1- on the shock absorber.

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-- Engage the boot groove at the shock absorber -arrow-.

NOTE:

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 boot -arrows-.

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-- Extend the shock absorber line, for example, 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-.

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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 counter-holding at the hex fitting -3-.

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Ratchet (commercially available)
Wrench - Strut Socket - 21mm: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.

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-- The pressure-holding valve -1- points toward the hole for the coupling rod -2-.

NOTE:

During alignment, only rotate at the rolling piston -item ) FRONT AIR SPRING SHOCK ABSORBER COMPONENTS - Rolling Piston in order to avoid damaging the rolling bellows -item ) FRONT AIR SPRING SHOCK ABSORBER COMPONENTS - BOOT inside the air spring.

-- Install the cover -3- and secure with the bolts -2-.

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Vehicles with Non-Bonded Grommet

-- Insert the grommet -1- in the cover -3-.

Continuation for Both Versions

-- Conduct the cable through the grommet.

-- Insert the cable socket in the connector housing.

-- Install the air spring shock absorber but do not connect the air line yet. Refer to AIR SPRING SHOCK ABSORBER, REMOVING AND INSTALLING .

-- Using the Engine and Gearbox Jack:VAS6931 , raise the air spring shock absorber until the piston -1- is lying on the anti-extraction device -arrow-.

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-- Press the anti-extraction device into the piston using the Trim Removal Wedge:3409 .

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Trim Removal Wedge:3409

-- Continue lifting the air spring shock absorber using the Engine and Gearbox Jack:VAS6931 until the welded ring on the shock absorber tube is approximately 3 mm inside the extraction piston -arrow-.

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-- When draining, hold the pressure retaining valve open by opening the valve plunger with a 5 mm hex wrench so that the air can flow through.

NOTE:

This will prevent the dust boot from creasing.

-- Slide the boot onto the air spring.

The air line has two markings.

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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. Refer to WHEEL BOLT TIGHTENING SPECIFICATIONS .

-- Fill The Air Spring Shock Absorber With The Vehicle Diagnostic Tester.