Installing Front Spring Strut (Air Springs)

Information 

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Dimension -X-  : lower edge of wing to center of axle (shown as an example)

• All screws and bolts on the axle must be tightened in vehicle position. Vehicle position means: vehicle resting on its wheels, or the wheel suspension is lifted with a universal jack. -Dimension X- from lower edge of wing to center of axle corresponds to vehicle position. For the current height values, please refer to the adjustment values for suspension alignment 

  > 4495TW ADJUSTMENT VALUES FOR SUSPENSION ALIGNMENT .

• Visually inspect all parts. 
• Replace self-locking nuts. 
• Replace all expansion screws (screws fitted using torque angle tightening procedure). 
• Use correct tightening torques and torque angle. 

  > Refer to the appropriate Tightening Torques For Front Axle service information

Information 

• Check the torque on the pressure control valve. 

Information 

• Do not remove air-spring strut from transport packaging until it has been filled. This will prevent damage to the inner bellows. 
• During assembly work, make sure that there are no pressure marks on the protective boot of the air-spring strut. 

Information 

• The air-spring strut must only be filled with the approved gasses, nitrogen or oil-free compressed air. 
• In some cases, up to 11 bar overpressure (upper tolerance, spring strut depressurized) is required to open the pressure control valve. 
• Fill the air-spring strut using several individual pressure shots. Filling the air with individual pressure shots will prevent the air-spring strut from being filled with too much overpressure. 
• Do not fill the air-spring strut with overpressure of more than 2.5 bar. 

Information 

• When working on the air-spring strut, make sure that the air-spring strut does not become twisted. 
• The air-spring struts are pre-filled to approx. 2.5 bar overpressure ex-works. If a new air-spring strut is installed, air can diffuse (escape) from the bellows of the air-spring strut as a result of storage times of varying duration. If the air-spring strut is removed from the transport packaging and installed without being filled, the bellows can fall into folds, thereby damaging the air-spring strut. For this reason, all air-spring struts must be re-filled prior to use. The procedure is described in detail in the course of the repair instructions. 

  >4301IN FILLING SPECIFICATION FOR AIR-SPRING STRUT 

1. Insert the spring strut -1-  into the vehicle -A-  .

   Check that the screws are seated correctly.

   Guide the wiring harness through the opening in the spring strut mount.

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   Installing spring strut

2. Remove the protection cap at the top of the spring strut if necessary.
3. Check that the pull-ring -1-  is seated correctly.

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   Pull-ring seating (shown with protection cap)

4. For V8: 

   Check that the torque support holder -1-  is seated correctly.

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   Installing torque support holder (shown with protection cap)

   Information 

   Always check for correct insertion depth of plug connections for the compressed air hoses:

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   Checking color markings

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   Checking dimension

   • Only one color marking (one white ring) must be visible on the connection. 
   • If two color markings (two white rings) are visible, the correct insertion depth has not been reached. 
   • - The dimension -x- from the end of the compressed air hose to the push-on connector must be at least 8.0 mm. 
5. Fit the pressure line -1-  to the pressure control valve -2-  using insert tool T10212 > T10212 - insert tool 

   > Tightening torques

   Then clip the pressure line into the retaining devices.

   > Tightening torque 12 Nm (8.9 ftlb.) + 3 Nm (2.2 ftlb.)

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   Pressure line for rear spring strut

6. Screw in and tighten fastening nuts -1-  on upper spring strut.

   > Refer to the appropriate Tightening Torques For Front Axle service information

   > Tightening torque 60 Nm (44 ftlb.)

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   Upper spring strut (air spring) mounting

7. Clip in -A-  connect and lock -a-  electric plug connection -1-  .

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   Installing plug connection for spring strut

8. Clip -B-  wiring harness into the holder -2-  .