TSB : Self-leveling suspension, servicing: Notes

Details

The system is bled automatically while driving. The self-leveling suspension is adjusted by way of an adjustable-length connecting link between the level control valve and a lever attached to the stabilizer bar of the rear axle. See SELF-LEVELING SUSPENSION, ADJUSTING . Counterhold the corresponding components when tightening hydraulic connections. When fluid circuit has been opened always: Check all unions for leaks, start engine and perform visual inspections. Check hydraulic fluid level with unladen vehicle, top off fluid if necessary. See CHECKING OIL LEVEL, BLEEDING STEERING SYSTEM AND CHECKING FOR LEAKS . NOTE: Items -1- to -21- apply to 6- and 8- cylinder-engines. NOTE: Items 1 to 37 in the following list are illustrated in Fig 1 . Filler cap with dipstick Strainer for reservoir Use solvent to clean Reservoir Re-fill with hydraulic fluid, Part No. G 002 000, capacity: 3 liters Plugged into hydraulic unit bracket Checking hydraulic fluid level on unladen vehicle. See CHECKING OIL LEVEL, BLEEDING STEERING SYSTEM AND CHECKING FOR LEAKS . Clamp Always replace Tightening. See TIGHTENING CLAMP WITH VAG 1275 . Can also be replaced by screw-type hose clamp Clamp Always replace Tightening. See TIGHTENING CLAMP WITH VAG 1275 . Can also be replaced by screw-type hose clamp Clamp Always replace Tightening. See TIGHTENING CLAMP WITH VAG 1275 . Can also be replaced by screw-type hose clamp Return line Screwed into Item 13: 10 Nm (7 ft lb) Return line Fluid cooler to connector Return line Steering box to fluid cooler Pressure line, 15 Nm (11 ft lb) Return line, 15 Nm (11 ft lb) Pressure line, 15 Nm (11 ft lb) Return line, 15 Nm (11 ft lb) Hex nut, 10 Nm (7 ft lb) Retaining washer Clamp Bonded rubber bushing Nut with washer, 25 Nm (18 ft lb) Bracket Bolt with washer, 8 Nm (71 in lb) Fluid cooler Bolted to radiator Two versions with different line routings. NOTE: items -22- to -37- only apply to 6-cylinder engines. Bolt with washer, 8 Nm (71 in lb) Expansion hose Piston pump to pressure line Installation instructions. See INSTALLATION INSTRUCTIONS: HIGH-PRESSURE HOSE . Suction hose Part section with line Bolt with washer, 10 Nm (7 ft lb) Bracket Bolted to cylinder head Threaded connection, 50 Nm (37 ft lb) Seal Always replace Tandem pump, 6 cyl. engine Tandem pump consists of plunger and vane pump. Piston pump is assigned to self-leveling, vane pump to power-assisted steering Suction hose Part section Banjo bolt, 25 Nm (18 ft lb) Seal Always replace Seal Always replace Banjo bolt, 50 Nm (37 ft lb) Pipe, 40 Nm (30 ft lb) Screw to expansion hose; counterhold on hex of expansion hose. Secured to intake manifold by way of bolt with washer -Item 36- Bolt with washer, 8 Nm (71 in lb) Expansion hose Combined hose/line assembly, routed to steering box Fig 1: Exploded View Of Self-Leveling Suspension Components (1 Of 4) Courtesy of AUDI OF AMERICA, INC. NOTE: Items -38- to -47- only apply to 8-cylinder engines. NOTE: Items 1 to 21, and items 38 to 47 are illustrated in Fig 2 . Tandem pump, 8 cyl. engine Tandem pump consists of piston pump and vane pump. Piston pump is assigned to self-leveling, vane pump to power-assisted steering. Checking piston pump delivery. See SELF-LEVELING SUSPENSION, CHECKING . Removing and installing. See VANE PUMP, REMOVING AND INSTALLING . Seal Always replace Banjo bolt, 50 Nm (37 ft lb) Suction hose Seal Always replace Banjo bolt, 50 Nm (37 ft lb) Expansion hose Leads to steering box Seal Always replace Banjo bolt, 25 Nm (18 ft lb) Expansion hose Piston pump - pressure line Installation instructions. See INSTRUCTIONS FOR ATTACHING HIGH-PRESSURE HOSE TO TANDEM PUMP . Fig 2: Exploded View Of Self-Leveling Suspension Components (2 Of 4) Courtesy of AUDI OF AMERICA, INC. NOTE: Items 48 to 78 are illustrated in Fig 3 . Hex bolt Bracket Introduction of modified bracket as part of design enhancement Bracket is bolted to the trapezoidal link mount. An M12 x 1.5 x 95 bolt with washer, shim and self-locking nut are used for this purpose Tightening torque: 70 Nm (52 ft lb) plus additional 90° (1/4 turn) Level control valve Checking function. See CONTROL VALVE, CHECKING FUNCTION . Checking for leaks. See CONTROL VALVE AND SPRING CYLINDER, CHECKING LEAKS . Return line, 15 Nm (11 ft lb) Connection of level control valve to manifold -Item 67- Pressure line, 15 Nm (11 ft lb) Distribution piece -Item 55- joint/right rear longitudinal member Return line, 15 Nm (11 ft lb) Disconnection point at left rear manifold. See DISCONNECTION POINT AT LEFT REAR WHEEL HOUSING . Pressure line, 15 Nm (11 ft lb) Disconnection point at left rear level control valve. See DISCONNECTION POINT AT LEFT REAR WHEEL HOUSING . Connector Pressure lines Pressure line 15 Nm (11 ft lb) Connector -item 55- / connector -item 77- Pressure line 15 Nm (11 ft lb) Level control valve / connector -item 55- Hex bolt, 20 Nm (15 ft lb) Washer Hex bolt, 10 Nm (7 ft lb) Seal Always replace Seal Always replace Banjo bolt, 25 Nm (18 ft lb) Fluid return line, 15 Nm (11 ft lb) Manifold / disconnection point at left rear longitudinal member Ring piece Fluid return line, 15 Nm (11 ft lb) Manifold / disconnection point at right rear longitudinal member Manifold Return line/fluid return lines Washer Hex nut, 10 Nm (7 ft lb) NOTE: Items -70- to -74- are in mirror-image arrangement on left and right of vehicle. Spring cylinder is removed with the pressure line -Item 71-. Loosen pressure line on right side of joint -Item 71- and -Item 52-. On the left side at disconnection point on left rear longitudinal member -Item 78-. Return line Tighten to 15 Nm (11 ft lb) at disconnection point -item 66-. CAUTION: Tighten 10 Nm (7 ft lb) at rear wheel housing/spring cylinder disconnection point. Pressure line 15 Nm (11 ft lb) Disconnection point at right rear longitudinal member / spring cylinder Note installation position at spring cylinder. See INSTALLATION POSITION OF PRESSURE LINE AT SPRING CYLINDER . Pressure line must be handled with care when removing spring cylinder. Do not bend. Banjo bolt, 20 Nm (15 ft lb) Sealing ring Always replace Spring cylinder with pressure accumulator NOTE: The spring cylinder is removed with the pressure line -Item 71-. Removing and installing. See SHOCK ABSORBER . Check spring cylinder. See CONTROL VALVE AND SPRING CYLINDER, CHECKING LEAKS . Check pressure accumulator. See PRESSURE ACCUMULATOR, CHECKING . Bracket Bleed valve, 15 Nm (11 ft lb) Connector Pressure line 15 Nm (11 ft lb) Connector -item 77- / disconnection point at left rear longitudinal member Fig 3: Exploded View Of Self-Leveling Suspension Components (3 Of 4) Courtesy of AUDI OF AMERICA, INC. NOTE: Items 79 to 89 are illustrated in Fig 4 . Hex bolt Lever Stabilizer bar Rubber bushing Clamp Self-locking nut, 10 Nm (7 ft lb) Always replace Direction of travel Self-locking nut, 5 Nm (44 in lb) Always replace Connecting link Adjustable length for adjusting self-leveling suspension: Loosen hex nut -arrow-, adjust connecting link length, tighten nut to 2 Nm (18 in lb). Securing plate Self-locking nut, 5 Nm (44 in lb) Always replace Fig 4: Exploded View Of Self-Leveling Suspension Components (4 Of 4) Courtesy of AUDI OF AMERICA, INC.