Rear 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
Guide Pins:T10093
Torque Wrench 1332 40-200 Nm :VAG1332
Spring Compressor Kit - Spring Tensioner:VAG1752/1
Spring Compressor Kit - Strut Clamping Block:VAG1752/20
Spring Compressor Kit - Spring Retainer with Inserts:VAG1752/3A
Spring Compressor Kit - Spring Retainer w/Inserts:VAG1752/7
Release Tool Set:VAS1978/35
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 .

Fig 1: Press With The Thumbs On The Air Spring Bead.

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NOTE:

Check whether the air spring is still filled with a residual pressure of 3 bar (43.5 psi).

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

-- Pull the boot downward off of the shock absorber and remove.

-- Clamp the Spring Compressor Kit - Strut Clamping Block:VAG1752/20 -1- in a vise.

Fig 2: Tension The V.A.G 1752/20 -1- In A Vice.

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-- Tighten the air spring damper in the Spring Compressor Kit - Strut Clamping Block:VAG1752/20 -1-.

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

-- Unclip the cable guide -3-.

-- Remove the grommet -arrow- from the cover -2-.

Fig 3: Install The Bolts -1- And Install The Cover -2-.

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-- Unscrew the bolts -1- and remove the cover -2-.

-- Conduct the cable through the grommet.

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

Fig 4: Install The Nut From The Mount While Counterholding At The Hex Fitting -3-.

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Ratchet (commercially available)
Wrench - Strut Socket - 21mm:3186

-- Remove the mount from the shock absorber.

-- Insert the Guide Pins:T10093 -1- into the air spring shock absorber mount.

Fig 5: Insert The T10093 -1- Into The Air Spring Shock Absorber Mount.

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NOTE:

The Guide Pins:T10093 act as a counterhold for the Spring Compressor Kit - Spring Retainer w/Inserts:VAG1752/3A -2-.

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.

-- Press the air spring rolling piston -1- off the shock absorber using the Spring Compressor Kit - Spring Tensioner:VAG1752/1 .

Guide Pins:T10093
Spring Compressor Kit - Spring Retainer with Inserts:VAG1752/3A
Spring Compressor Kit - Strut Clamping Block:VAG1752/20
Rolling Piston
Spring Compressor Kit - Spring Retainer w/Inserts:VAG1752/7
Rubber mat or similar item
Outer Guide
Spring Compressor Kit - Spring Tensioner:VAG1752/1

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 -4- does not slip down out of the outer guide -7-.

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-.

Fig 6: Even Circumferential Folds On Rolling Bellows

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Air Spring Shock Absorber, Assembling

Fig 7: Identifying Sealing Rings -Arrows-

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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.

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-.

Fig 8: Even Circumferential Folds On Rolling Bellows

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-- Extend the shock absorber line, for example, with a cable, so that it can be routed through the air spring.

-- Ensure that the buffer stop -1- is seated properly in the cover -2- -arrow-.

Fig 9: 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-.

Fig 10: Install The Nut From The Mount While Counterholding At The Hex Fitting -3-.

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Ratchet (commercially available)
Wrench - Strut Socket - 21mm:3186

-- Insert the cable socket in the connector housing.

-- Reinstall the cable guide -3- and clip.

-- Install the cover -2- and tighten the bolts -1-.

Fig 11: Install The Bolts -1- And Install The Cover -2-.

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-- Insert the grommets -arrows- in the cover -2-.

-- Align the air spring so that the pressure retaining valve -1- is located near the imaginary axis of symmetry -arrow- (approximately 10° offset from the center) on the air spring shock absorber.

Fig 12: Holding Valve -1- Is Located Near Imaginary Axis Of Symmetry -Arrow

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NOTE:

Only rotate at the rolling piston -item ) REAR AIR SPRING SHOCK ABSORBER COMPONENTS - ROLLING PISTON in order to avoid damaging the rolling bellows -item ) REAR AIR SPRING SHOCK ABSORBER COMPONENTS - BOOT inside the air spring.

-- 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-.

Fig 13: 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 .

Fig 14: Press The Anti-Extraction Device Into The Piston Using The 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-.

Fig 15: Welded Ring On Shock Absorber Tube

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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.

-- Slide the boot over the shock absorber so that the boot groove engages.

The rear air line is covered with shrinkable tubing.

Fig 16: Shrinkable Tubing -2- Is In Contact With The Union Nut -1-.

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-- Insert the air line until the end of the shrinkable tubing -2- is in contact with the union nut -1-.

The end of the shrinkable tubing may be a maximum of 2 mm in front of the union nut.

-- Screw on the air line with the union nut -1- at the air spring shock absorber.

Fig 17: Identifying Union Nut -1- Of Air Line

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-- Fill the rear air spring shock absorber with the Vehicle Diagnostic Tester.

-- Install the wheel and tighten. Refer to WHEEL BOLT TIGHTENING SPECIFICATIONS .