Dynamic Ride Control (DRC), Draining And Filling: Notes

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Special Tools And Workshop Equipment Required

DRC Filling Device :VAS6209/4
The DRC Filling Device :VAS6209/4 serves as an upgrade to the DRC Charging Device :VAS6209 already found in dealerships.
Retrofit Kit, DRC System :VAS6209/5
The Retrofit Kit, Retrofit Kit, DRC System :VAS6209/5 is needed if the dealership has the DRC Charging Device, Pressure Pump:VAS6209/3 and wants to upgrade the Filling Device for DRC System :VAS6544 . The DRC System Supplementary Kit :VAS6209/6 is also necessary.
DRC System Supplementary Kit :VAS6209/6
The Supplement Kit, DRC System :VAS6209/6 is needed to upgrade the DRC Charging Device, Pressure Pump :VAS6209/3 to the Filling Device for DRC System :VAS6544 . The requirement is that the dealership already has the DRC Charging Device :VAS6209 . If the dealership does have the DRC Charging Device :VAS6209 , then the Retrofit Kit, DRC System :VAS6209/5 must also be obtained.
DRC Filling Device :VAS6544

NOTE:

Extracting, Evacuating And Filling The Whole DRC line (Lines/Shock Absorber And Central Valve) Is Performed With The :VAS6544 Depending On The DRC System Equipment In The Dealership, The Equipment May Need To Modified Or Updated To Match :VAS6544 . The Following Choices Are Possible:

NOTE:

Updating The Equipment For The DRC System Must Be Done One Time Only. It Is Not Necessary To Convert Back Again. The Procedure For Draining And Filling The Complete DRC System Is Described Using The :VAS6544 .

Only approved oil for filling and draining must be used.

As a replacement part, shock absorbers and lines are delivered empty.

Filling must only be performed at ambient temperature of approximately 20 °C (68 °F).

Lines/shock absorbers and central valves may only be suctioned, evacuated and filled when they are installed and connected.

CAUTION:

Extracting, evacuating and filling the DRC line on vehicles with the variable damping may be performed only when the damping setting is set to "COMFORT".
To extract, evacuate and fill the DRC line, start the Fill DRC >>function<< on the Vehicle Diagnostic Tester under address word 14 in "Guided Functions".
If the mode is activated, the system goes into "COMFORT" mode and can no longer be changed manually. The yellow warning lamp in the instrument cluster turns on when filling mode is active.

While filling the DRC system, the gas reservoir to the pressure clamps is automatically checked for leaks at the piston in the central valve.

WARNING:

Always Wear Safety Goggles!

Valves Of Filling Device Are Open When Ratchet Levers Are Parallel To Direction Of Flow.

NOTE:

The Valves Must Be Kept Closed During Transport And Storing The :VAS6544 .

Lines must not be bent.

Required Equipment

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Not Required
Not Required
Fill lines with Quick-Release Fastener
Venturi Injector with Exhaust Hose
- From the :VAS6209
Connecting Hose
- From the :VAS6209
:VAS6544
Container for Used Oil
- Empty before starting the work
- Identification: red dot

NOTE:

Before filling the DRC system, make sure the oil reservoir for the :VAS6544 and the line between the pressure pump and oil reservoir are filled with oil.

The used oil container on the :VAS6544 must be empty and must be emptied after each charge.

Drain Old Oil Reservoir

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-- Remove the cap -arrow- from the old oil reservoir -1- and drain the old oil.

-- Install the cap -arrow- on the old oil reservoir -1-.

:VAS6544 Filling and Bleeding

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-- Fill the oil reservoir -2- with new oil up to the marking and position the O-ring to the height of the oil level.

-- Close the shut-off valve -A and C- on the :VAS6544 .

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-- Close the needle valve -B-.

-- Connect the hose -2- to the old oil reservoir -arrow- and to the quick-release fastener -4- on the :VAS6544 .

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-- Connect the Venturi injector -3- and vent hose to the old oil reservoir -arrow- as illustrated.

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-- Connect the compressed air to the Venturi injector -3-.

-- Open the locking valve -C-.

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-- Open the locking valve -A- briefly, for approximately one to two seconds, until the connecting line -1- between the oil reservoir -2- and pressure pump is filled and does not contain bubbles.

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-- Close the locking valve -C-. Remove the compressed air connector form the Venturi injector.

Extracting/Evacuating

CAUTION:

Extracting, evacuating and filling the DRC line on vehicles with the variable damping may be performed only when the damping setting is set to "COMFORT".
To extract, evacuate and fill the DRC line, start the Fill DRC >>function<< on the Vehicle Diagnostic Tester under address word 14 in "Guided Functions".
If the mode is activated, the system goes into "COMFORT" mode and can no longer be changed manually. The yellow warning lamp in the instrument cluster turns on when filling mode is active.

WARNING:

Always Wear Safety Goggles!

-- In vehicles with variable damping, start the Fill DRC >>function<< on the Vehicle Diagnostic Tester under address word 14 in "Guided Functions" .

-- Turn the front wheel on the side to be suctioned toward the outside.

NOTE:

The DRC System Consists Of Two Separate Hydraulic Systems. The Central Valves Are Connected Diagonally To The Applicable Shock Absorber.

-- Drain The DRC System As Follows:

Central Valve	Shock Absorber
1 - Left	Left front/right rear
2 - Right	Right front/left rear

-- Remove the dust cap from the front suction/fill valve.

-- Connect the fill line and quick-release fastener -1- from the :VAS6544 -Item ) DYNAMIC RIDE CONTROL (DRC), DRAINING AND FILLING to the front suction/fill valve on the line to be suctioned.

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-- Remove the rear wheel on the side of the line to be suctioned.

-- Free up the wheel housing liner for the rear suction/fill valve.

-- Remove the dust cap from the rear suction/fill valve.

-- Connect the fill line and quick-release fastener -1- from the :VAS6544 -Item ) DYNAMIC RIDE CONTROL (DRC), DRAINING AND FILLING to the rear suction/fill valve on the line to be suctioned.

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-- Connect the fill lines -Item ) DYNAMIC RIDE CONTROL (DRC), DRAINING AND FILLING to the connections -A and B- on the :VAS6544 .

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The shut-off valve -A and C- on the :VAS6544 closed.

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Needle valve -B- closed.

The hose -2- is connected to the used oil container -arrow- and to the :VAS6544 -4-.

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Venturi injector -3- connected to the old oil reservoir vent hose -arrow- on the :VAS6544 .

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Compressed air to the Venturi injector -3- connected.

-- Open the valve -C- until the last of the oil is extracted from the DRC system. (Visible on the return hose -2- to the used oil reservoir).

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-- When the pressure manometer shows approximately negative 0.9 bar (13 psi), close the valve -C- and disconnect the compressed air hose from the Venturi injectors.

Check for leaks.

NOTE:

Vacuum must be stable for at least two minutes at negative 0.9 bar (13 psi).

-- Check the oil level on the oil reservoir, fill with new oil up to the marking if necessary and position the O-ring to the height of the oil level.

CAUTION:

Extracting, evacuating and filling the DRC line on vehicles with variable damping may only be performed when the damping setting is set to "COMFORT".