Installing Front Spring Strut (Air Springs)

Information 

• 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 .
  Fig 1: Checking Dimension X - Lower Edge Of Wing To Centre Of Axle

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• 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  . → 4X00IN TIGHTENING TORQUES FOR FRONT AXLE

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 wire harness through the opening in the spring strut mount.

   Fig 2: Installing Spring Strut

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2. Remove the protection cap at the top of the spring strut if necessary.
3. Check that the pull-ring -1-  is seated correctly.
   Fig 3: Identifying Pull-Ring Seating (With Protection Cap)

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4. For V8: 

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

   Fig 4: Identifying Torque Support Holder (With Protection Cap)

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   Information 

   • Check the torque on the pressure control valve  .
5. Fit pressure line -1-  to the pressure control valve -2-  using insert tool T10212 insert tool T10212  , → Tightening torques  . Then clip the pressure line into the retaining devices.
   Fig 5: Identifying Pressure Line For Rear Spring Strut

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6. Screw in and tighten fastening nuts -1-  on upper spring strut. → 4X00IN TIGHTENING TORQUES FOR FRONT AXLE
   Fig 6: Identifying Upper Spring Strut Mounting (Air Spring)

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7. Plug in electric plug connection -1-  for the spring strut -A-  and lock it -a-  .
   Fig 7: Installing Plug Connection For Spring Strut

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8. Clip wire harness into the holder -2-  (-B-  ).