Suspension strut, removing and installing

WARNING: This page does not describe the selected car, but rather 17 other vehicles, including the 2009 Audi S4, 2009 Audi A4, 2008 Audi S4, 2008 Audi RS 4, and 2008 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Engine/Transmission Jack V.A.G. 1383 A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine/transmission jack V.A.G 1383 A
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332

Removing

On vehicles with Dynamic Ride Control (DRC II), empty and fill system → Dynamic Ride Control (DRC II), emptying and filling

Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
Remove wheel.
Secure brake disc with a wheel bolt.
Before removing left suspension strut, level control system sensor link must be loosened from link on vehicles with headlight range control module by opening retaining clip → Vehicles with automatic headlight vertical aim control, vehicle level sensor .

Unclip ABS line from bracket at brake caliper.

Vehicles with brake caliper HP-2

Fig 2: Identifying Hex Bolt, Brake Line Bracket, Brake Caliper Bolts And Brake Caliper

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove hex bolt - 2 - and remove brake line bracket.
Remove bolts - 1 - from brake caliper and remove brake caliper.
Reinstall brake line bracket. Install hex bolt - 2 - and tighten.
Secure brake caliper to body so that caliper weight does not bend or damage brake line.

Continued for all vehicles

Remove brake caliper and secure to body so that weight of caliper does not stress or damage brake hose or brake line.

Fig 3: Removing Clip, Nut, Hex Bolt And Control Arms

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove clip - 1 - with a pair of pliers.

This clip does not need to be inserted again.

Remove - 2 - , remove hex bolt and remove both control arms upward.

The slits in the wheel bearing housing must not be widened using a chisel or similar tool!

Protect steering gear boot from damage with a protective sleeve.

For clarity the illustration shows a steering gear that has been removed.

Protective sleeve - 1 - can be ordered under part number 893 512 137.

Fig 4: Identifying Protective Sleeve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

A 20 to 25 mm strip, dimension - A - , must be cut out of protective sleeve - 1 -.
Carefully deburr cut surfaces.
Slide protective sleeve over steering gear boot. The open side of sleeve must point downward.

In order not to damage lower link joints, it is necessary to brace against too strong rebound, e.g. using engine/transmission jack V.A.G 1383 A.

Fig 5: Removing Hex Bolt From Suspension Strut/Control Link

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove hex bolt - arrow - from suspension strut/control link.
Swing wheel bearing housing to side.
Loosen coolant reservoir connection.
Remove plenum chamber cover.

Fig 6: Remove Screw Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screw cover - arrow -.

Fig 7: Removing/Installing Hex Bolts In Plenum Chamber

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove hex bolts - 1 - in plenum chamber.
Take out suspension strut with mounting bracket.

Do not damage protective joint boot when doing this!

Installing

Fig 8: Removing/Installing Hex Bolts In Plenum Chamber

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert suspension strut with mounting bracket into suspension turret. Tighten hex bolts - 1 -.

NOTE:

Make sure that washers are seated correctly.

Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position → Wheel bearing, lifting to curb weight position

Fig 9: Identifying Guide Link/Subframe Connection Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert suspension strut forked head into control arm and tighten threaded connection - 1 -

NOTE:

Bolt must be inserted opposite direction of travel.

Fig 10: Inserting Both Upper Link Joint Pins In Wheel Bearing Housing And Bend Downward As Much As Possible Using Pliers T40067

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert both upper link joint pins in wheel bearing housing and bend downward as much as possible using pliers T40067.

Fig 11: Inserting Suspension Strut Forked Head Into Link

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert new bolt - 2 - and self-locking nut and tighten
Insert ABS wiring into retainer on brake caliper.
Install brake disc, install and tighten brake caliper. → 46 - BRAKES - MECHANICAL COMPONENTS
On vehicles with headlight range control, install vehicle level sensor link at control arm → Vehicles with automatic headlight vertical aim control, vehicle level sensor .

Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide