Empty used oil container

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CAUTION: Protective eye wear must be worn for all procedures!

Fig 1: Empty Used Oil Container

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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.

Fig 2: Empty Used Oil Container

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 Fill new oil container
Empty used oil container ahead of time Empty used oil container

Suctioning:

Fig 3: Removing/Installing Plastic Cover

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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 → Central valve and connections to suspension struts

Fig 4: Locating Lock Nut On Line To Be Checked & Screwing In Shut-Off Screw Until It Is Hand Tight

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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.

Fig 5: Connecting Adapter V.A.S 6209/1 To Line To Be Suctioned

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Connect adapter V.A.S 6209/1 to line to be suctioned.

Fig 6: Performing Suction Procedure

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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 -.

Fig 7: Performing Suction Procedure

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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.

Fig 8: Opening Line Connection At Strut

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Open line connection - 1 - at strut approx. one turn and suction oil out until as little remains as possible.

Fig 9: Performing Suction Procedure

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To shorten suction process, valve - D - should be quickly and regularly opened lightly and closed again immediately during the suction process.

Fig 10: Performing Suction Procedure

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Perform suction procedure until there is no more oil in connecting hose - 2 -.

Fig 11: Opening Line Connection At Strut

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Close line connection - 1 - to strut again.

Evacuating:

"Suctioning" step must be performed.

Fig 12: Performing Evacuating Procedure

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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.

Fig 13: Performing Evacuating Procedure

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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.

Fig 14: Performing Evacuating Procedure

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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.

Fig 15: Performing Evacuating Procedure

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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.

Fig 16: Locating Lock Nut On Line To Be Checked & Screwing In Shut-Off Screw Until It Is Hand Tight

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 → DRC II system pressure check