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

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Special tools and workshop equipment required

DRC Filling Device VAS6209/4 serves as an upgrade to DRC Charging Device VAS6209
Retrofit Kit, DRC System VAS6209/5 is needed if dealership has DRC Charging Device, Pressure Pump VAS6209/3 and wants to upgrade Filling Device for DRC System VAS6544
Supplement Kit, DRC System VAS6209/6 is needed to upgrade DRC Charging Device, Pressure Pump VAS6209/3 to Filling Device for DRC System VAS6544. Requirement is that dealership already has DRC Charging Device VAS6209 and Retrofit Kit, DRC System VAS6209/5 must also be obtained.
DRC Filling Device VAS6544

NOTE:

Extracting, evacuating and filling the whole Dynamic Ride Control (DRC) System line (lines/damper and central valve) is performed with the DRC Filling Device VAS6544. Depending on the Dynamic Ride Control (DRC) System equipment in the dealership, the equipment may need to modified or updated to match the DRC Filling Device VAS6544. The following choices are possible:

NOTE:

Updating the equipment for the Dynamic Ride Control (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 Filling Device for DRC System VAS6544.

Only approved oil for filling and draining must be used. Refer to appropriate FLUID CAPACITY TABLE information.

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/dampers and central valves may only be evacuated and filled when they are installed and connected.

NOTE:

The shut-off valve for the wiring harness at the central valve must remain open when extracting, evacuating and filling the DRC system (lines/damper and central valve).

CAUTION:

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

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 indicator 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 DRC Filling Device VAS6544.

Lines must not be bent.

Required equipment

Fig 1: Identifying Dynamic Ride Control (DRC), Draining And Filling Components

Courtesy of AUDI OF AMERICA, LLC

Front Shock Absorber Adapter
- Not for this model
Rear Shock Absorber Adapter
- Not for this model
Fill Lines with Quick-Release Fastener
Venturi Injector with Exhaust Hose
- From the DRC Charging Device VAS6209
Connecting Hose
- From the DRC Charging Device VAS6209
DRC Filling Device 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 DRC Charging Device VAS6544 and the line between the pressure pump and oil reservoir are filled with oil.

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

Drain the Old Oil Reservoir.

Fig 2: Filling Oil Reservoir -2-

Courtesy of AUDI OF AMERICA, LLC

-- 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-.

DRC Filling Device VAS6544 Filling and Bleeding

Fig 3: Filling Oil Reservoir -2-

Courtesy of AUDI OF AMERICA, LLC

-- 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 DRC Filling Device VAS6544.

Fig 4: Opening Needle Valve -B-

Courtesy of AUDI OF AMERICA, LLC

-- Close the needle valve -B-.

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

Fig 5: Connecting Compressed Air To Venturi Injector -3- And Opening Locking Valve -C-

Courtesy of AUDI OF AMERICA, LLC

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

Fig 6: Connecting Compressed Air To Venturi Injector -3- And Opening Locking Valve -C-

Courtesy of AUDI OF AMERICA, LLC

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

-- Open the locking valve -C-.

Fig 7: Closing Locking Valve -C-

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Fig 8: Closing Locking Valve -C-

Courtesy of AUDI OF AMERICA, LLC

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