Installing Air Spring Bellows

Information 

To prevent damage to the air springs, pay particular attention to the following points when handling air springs:

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Air spring

• Never lower a vehicle with empty air springs. 
• Do not pull the air spring apart. 
• Do not bend the air spring out of shape (the air spring can be bent by < 20°). 
• Do not lift the air spring at the electric connector. 
• Carefully hold the air spring only at the top and bottom of the cover -1- or at the protective bellows -2-  .

1. Replace clip -1-  .

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   Replacing clip

2. Place air spring bellows in installation position.
3. Clip air spring bellows at the top into the body mounting points -1-  .

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   Upper clip on air spring bellows

4. Route electric line -1-  in the guides on the air spring bellows.

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   Electric line on air spring bellows

5. Secure plug connections on the air spring bellows -1-  .

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   Plug connections on air spring bellows

   1. 5.1 Connect and lock electric connectors -2-  .

      Information 

      Check the following before installing the air line:

      • Check that the cutting ring -1-  and Voss threaded joint -2-  are on the air line -3-  (not relevant if the air spring bellows was replaced and the Voss threaded joint that is pre-fitted on the air spring bellows is used).
      • Check that the air line is fitted correctly.

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      Checking air line

      Only one marking -1-  on the air line should be visible.

      Pull the air line briefly against the insertion direction. If it cannot be pulled out, the air line is fitted correctly.

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      Checking that air line is fitted correctly

   2. 5.2 Connect air line and tighten Voss threaded joint on the air line -3-  > Tightening torque 2 Nm (1.5 ftlb.) 
6. Secure rear upper control arm -1-  on the wheel bearing housing.

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   Mounting for rear upper control arm on wheel bearing housing

   1. 6.1 Install threaded joint -2-  (do not tighten!).
      WARNING: Wheel bearing housing raised incorrectly 

      • Risk of crushing 
      • Risk of damage to components 

        → Wear personal protective gear.

        → Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).

      Information 

      Threaded joints must only be tightened in zero position to prevent warping in the bearings.

   2. 6.2 To tighten the threaded joints, lift the wheel bearing housing as far as required using lifting equipment (e.g > VAS 6931 - Transmission and Engine Jack  ) until the lower trailing arm is horizontal > Zero position 

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      Zero position

   3. 6.3 Tighten threaded joint -2-.  > Initial tightening 70 Nm (52 ftlb.)  > Final tightening torque angle + 90°