Table of contents: Removal and installation the shock… ↓ Creating pressure in the shock… ↓ Shock absorber maintenance ↓
1. The installation details of the spring strut suspension are shown on illustrations 1.1c.
Removal and installation the shock absorber
2. The air shock absorber is removed together with the upper arm and its bracket. During work, do not allow dents to form in the shock absorber boot.
3. Remove the air intake chamber cover (see Section 19 of Chapter 1).
4. Remove the wheel and wheel arch liner.
5. Clean the area around the connection (1 in illustration 2.7a) on the residual pressure valve (2) and unscrew this connection. Seal both openings.
6. Unscrew the nut (2 in illustration 4.3) and disconnect the connector (3).
7. Disconnect the connector (2 in the illustration) front left shock absorber valve and unhook the wire.
6.7. Front left shock absorber valve connector.
8. Disconnect the drive shaft from the front final drive (3 in illustration 7.7 Chapter 7) and unscrew the bolt (2).
9. Secure the VW552 compression tool into the opening at the top of the wheel arch (And in the illustration) and on the upper arm (B).
6.9. Fixing the upper arm.
Use this tool to select the weight of the upper control arm.
10. Remove the bolts (1-3 in illustration 5.20).
11. Unload the suspension (see Section 2) and remove the VW552 upper control arm holding tool.
12. Separate the upper suspension arm from the steering knuckle (see Figure 7.9 in Chapter 7) and the steering rod end (see illustrations 7.8 Chapter 7).
13. Unscrew the bolt nut (1 in illustration 7.7 Chapter 7) fastening the shock absorber to the lower arm.
14. Lower the steering knuckle as far as necessary (see illustration 5.9).
15. Pull out the bolt (1 in illustration 7.7 Chapter 7) from the lower arm and remove the shock absorber.
16. Installation is carried out in reverse order. The new shock absorber must be pressurized before installation. Finally, adapt the basic position.
Creating pressure in the shock absorber
17. Shock absorbers are supplied with a minimum initial pressure, which may decrease after storage. Before removing the shock absorber from the packaging, the initial pressure should be restored, otherwise dents or bends may form on the shock absorber boot, which may lead to damage.
18. Remove the lid from the packaging, unscrew the hollow bolt from the residual pressure valve (see illustration) and close the valve.
6.18. Hollow bolt on the shock absorber valve.
19. Connect a cylinder of argon or Corgon welding mixture to the shock absorber, as shown in the illustration.
6.19. Connecting the compressor:
1 - Shock absorber in packaging;
2 - Cylinder with argon or Corgon welding mixture;
3 - Filling device T6231;
4 - Adapter T10157/1.
Note: Do not use other gases to inflate the shock absorber.
Set the limiting valve to 2.0 l/min and create a pressure of 3.5-4.5 bar (no more) in the shock absorber by briefly opening the valve several times.
Note: The correct pressure will be indicated after the value in the pressure holding valve is exceeded (approximately 3.5 bar).
20. Disconnect the filling device from the shock absorber. At the same time, the pressure holding valve will release excess pressure and leave only 3.5 bar.
21. After this, you can remove the shock absorber from the packaging. Once installed, use the suspension at max height, then switch to normal height, back to max, and back to normal to filter out the gas.
Shock absorber maintenance
22. During maintenance (replacement of parts) air shock absorber, follow the resistance. illustrations.
6.22a. Shock absorber design:
1, 8 - Sealing ring, subject to replacement;
2 - Cover, cannot be removed separately;
3 - Outer guide, cannot be removed separately;
4 - U-shaped boot, cannot be removed separately;
5 - Piston boot 4, cannot be removed separately;
6 - Dust cover, subject to replacement;
7 - Shock absorber.
6.22b. Shock absorber assembly parts:
1 - Bolts, 4 pcs., 30 Nm;
2 - Bracket;
3 - Nut, subject to replacement, 60 Nm;
4 - Support;
5, 10 - Sealing ring, subject to replacement;
6 - Residual pressure valve, 8 Nm;
7 - "Air Spring";
8 - Bumper;
9 - Shock absorber;
11 - Dust cover, subject to replacement;
12 - Clamp, subject to replacement.
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