Dynamic Ride Control (DRC), Draining And Filling

Special tools and workshop equipment required 

• Vehicle Diagnostic Tester
• DRC Filling Device:VAS6209/4 
  Fig 1: Identifying Upgrade Kit, Filling Device For DRC System VAS 6209/4

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Extracting, evacuating and filling the whole DRC line (lines/shock absorber and central valve) is performed with the DRC Filling Device:VAS6544  Depending on the DRC system equipment in the dealership, the equipment may need to be modified or updated with the supplement or retrofit set to match the version of the DRC Filling Device:VAS6544  . The following choices are possible:

The DRC Filling Device:VAS6209/4  serves as an upgrade to the DRC Charging Device:VAS6209  already found in dealerships.

Special tools and workshop equipment required 

• Retrofit Kit, Charging Device, DRC System:VAS6209/5 
  Fig 2: Identifying Retrofit Kit, DRC System VAS 6209/5

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The Retrofit Kit, Charging Device, 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.

Special tools and workshop equipment required 

• DRC System Supplementary Kit:VAS6209/6 
  Fig 3: Identifying Supplement Set, DRC System VAS 6209/6

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The DRC System Supplementary Kit:VAS6209/6  is needed to upgrade the DRC Charging Device, Pressure Pump:VAS6209/3  to the DRC Filling Device: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, Charging Device for DRC System:VAS6209/5  must also be obtained.

Special tools and workshop equipment required 

• DRC Filling Device:VAS6544 
  Fig 4: Identifying Charging Device For DRC System VAS 6544

  Courtesy of AUDI OF AMERICA, LLC

Required components from the DRC Filling Device:VAS6544 

1. Not Required
2. Not Required
3. Charging Hose with Quick-Release Fastener
4. Venturi Injector with Drain Hose
   • From the DRC Charging Device:VAS6209 
5. Connecting Hose
   • From the DRC Charging Device:VAS6209 
6. DRC Filling Device:VAS6544 
7. Used Oil Container
   • Empty before starting the work
   • Identification: red dot

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 DRC Filling Device:VAS6544  .

• Only approved oil may be used for filling or refilling. Refer to the Parts 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/shock absorbers and central valves may only be evacuated and filled when they are installed and connected.
• While filling the DRC system, the gas reservoir to the pressure clamps is automatically checked for leaks at the piston in the central valve.
• Valves of filling device are open when ratchet levers are parallel to the flow direction.
• The valves must be kept closed during transport and storing the DRC Filling Device:VAS6544  .
• Lines must not be bent.

• 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.

-- Remove the cap -arrow- from the used oil container -1- and drain the used oil.

-- Reattach the cap.

DRC Filling Device:VAS6544  Filling and Bleeding

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

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

-- Close the needle valve -B-.

-- Connect the hose -2- to the used oil container -right arrow- and to the quick-release fastener -4- on the DRC Filling Device:VAS6544  .

-- Connect the Venturi injector -3- to the vent hose on the used oil container -left arrow- as shown.

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

-- Open the locking valve -C-.

-- Open the locking valve -A- for approximately one to two seconds, until the connecting line -1- between the oil reservoir -2- and pressure pump is filled free of bubbles.

-- Close the locking valve -C-. Disconnect the compressed air connector from the Venturi injector.

Extracting/Evacuating

-- When the DRC is to be bled/evacuated, then select the "DRC, Filling (only RS models)" program. Refer to DIAGNOSTIC ENTRIES .

-- Start the selected program and follow the instructions on the Vehicle Diagnostic Tester display.

-- Turn the front wheel on the side to be evacuated outward.

The DRC system consists of two separate hydraulic systems. The central valves are connected diagonally to the applicable shock absorber.

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-- Drain the DRC system as follows:

Central Valve	Shock Absorber
A - left	Front right -3- / Rear left -4-
B - right	Front left -2- / Rear right -1-

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

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-- Connect the fill line and quick-release fastener -1- from the Charging Device For DRC System:VAS6544  -item 3-  DYNAMIC RIDE CONTROL (DRC), DRAINING AND FILLING => List Item:Charging Hose with Quick-Release Fastener to the front suction/fill valve on the wiring harness to be evacuated.

-- Remove the rear wheel on the side of the wiring harness to be evacuated. Refer to WHEELS AND TIRES .

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

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-- Connect the filling hose and quick-release fastener -1- from the DRC Filling Device:VAS6544  -item 3-  DYNAMIC RIDE CONTROL (DRC), DRAINING AND FILLING => List Item:Charging Hose with Quick-Release Fastener to the rear suction/fill valve on the wiring harness to be evacuated.

-- Connect the fill lines -item 3-  DYNAMIC RIDE CONTROL (DRC), DRAINING AND FILLING => List Item:Charging Hose with Quick-Release Fastener to the connections -A and B- on the DRC Filling Device:VAS6544  .

• The shut-off valve -A and C- on the DRC Filling Device:VAS6544  closed.
  Fig 12: Opening Needle Valve -B-

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• Needle valve -B- closed.

• The hose -2- is connected to the used oil container -right arrow- and to the DRC Filling Device:VAS6544  -4-.
  Fig 13: Connecting Compressed Air To Venturi Injector -3- And Opening Locking Valve -C-

  Courtesy of AUDI OF AMERICA, LLC
• Venturi injector -3- connected to the used oil container vent hose -left arrow- on the DRC Filling Device:VAS6544  .
• Compressed air connected to the Venturi injector -3-.

-- 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 container).

-- When the pressure manometer shows approximately negative 0.9 bar (13.05 psi), close the valve -C- and disconnect the compressed air hose from the Venturi injectors.

-- Check for leaks.

• Vacuum must be stable for at least two minutes at negative 0.9 bar (13.05 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. Refer to the Parts Information.

Filling

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The DRC system consists of two separate hydraulic systems. The central valves are connected diagonally to the applicable shock absorber.

-- Fill the DRC system as follows:

Central Valve	Shock Absorber
A - left	Left rear -4- / right front -3-
B - right	Rear right -1- / front left -2-

-- Open the needle valve -B- approximately two turns and let the oil run out of the oil reservoir on the DRC Filling Device:VAS6544  into the evacuated DRC system.

Oil flows out of the oil reservoir in the connected DRC system. This is shown by the decreasing the oil level in the oil reservoir. Depending on the amount of oil remaining after extraction, the procedure may take several minutes. As the system fills up, the oil level goes down slower. If the level of the oil no longer moves, the first step of the filling process is complete.

-- Close the needle valve -B-.

-- Open the valve -A- and fill the DRC system to 22 bar (319.08 psi) by pumping the lever on the hand pump -1- several times.

• While filling, make sure the oil reservoir on the DRC Filling Device:VAS6544  does not run dry; fill with reservoir with new oil if necessary.

• When a pressure of 22 bar (319.08 psi) is reached, close the valve -A- and do not pump the hand pump lever any more.

TIP:

• Exceeding the maximum pressure of 22 bar (319.08 psi) does not improve the filling process. Caution! There is a risk of damaging DRC system components as well as the DRC Filling Device:VAS6544  .
• If the pressure does not reach 22 bar (319.08 psi) or if it continually drops, check all connections for damage or leaks. If no issues are found on the outside, the gas reservoir to the pressure clamps on the piston on the inside of the central valve is leaking. Replace the central valve.

-- Open the needle valve -B- slightly and let the pressure drop to 16 bar (232.06 psi).

• Close the valve -B- when the indicator on the pressure manometer reaches the 16 bar (232.06 psi) marking.

TIP:

The 16-bar graduation line on the scale is colored in green depending and the version and model of the pressure gauge. The marking has no meaning for this procedure and should be ignored.

The DRC system is filled.

-- Disconnect the filling hose with quick-release coupling on the DRC Filling Device:VAS6544  -item 3-  DYNAMIC RIDE CONTROL (DRC), DRAINING AND FILLING => List Item:Charging Hose with Quick-Release Fastener from the rear and front suction/fill valve.

-- Mount the rear wheel. Refer to WHEELS AND TIRES .

-- Install the dust cap for the rear and front suction/fill valve.