Repairing front air spring strut: VW Touareg II

🧭 Before you start

Fits: VW Touareg II (7P, 2010–2018)

Don't miss

• To avoid damage, a rubber mat (6) or similar must be inserted between spring retainer insertsV.A.G 1752/7(5) and air spring plunger.
• If the shock absorber has not been replaced, the sealing rings (arrows) on the piston rod and the shock absorber tube must be replaced.
• Even slight soiling leads to air spring strut leakages.
• If the air spring is to be reused and the plunger has slipped out of the external guide, it must be pushed in again by forming an even fold all around the bellows (arrows).
• Make sure that bump stop (1) is correctly seated in cover (2)(arrow).

📋 Procedure

1. Remove air spring strut [Note: Check whether the air spring still has approx. 3 bar residual pressure.To do this, press bead of air spring with your thumb. The bead must offer perceptible resistance.If no great resistance is detectable, the air spring is unpressurised.]
2. Clamp air spring strut by the anti-roll bar mounting in a vice with protective jaws.
3. ⚠ Take care not to damage mounting. — Knock cable lugs out of connector of air spring strut using set of releasing toolsVAS 1978/35.
4. Unscrew bolts (2) and remove cover (3).
5. Push cable through grommet (1).

6. Unscrew nut from mount by counterholding it by the hexagonal piece (3).
7. Remove mounting from shock absorber.
8. Push bellows downwards.
9. Press air spring plunger (1) off from shock absorber using spring compressorV.A.G 1752/1. [Note: To avoid damage, a rubber mat (6) or similar must be inserted between spring retainer insertsV.A.G 1752/7(5) and air spring plunger.] [Note: If the air spring is to be reused and the plunger has slipped out of the external guide, it must be pushed in again by forming an even fold all around the bellows (arrows).]
10. ⚠ Insert protection, e.g. rubber, between spring retainer insertsV.A.G 1752/7 and air spring plunger.Insert protection, e.g. rubber, between spring retainersV.A.G 1752/3A and shock absorber.Ensure that the plunger (1) does not slip down and out of the external guide (2). — Pull bellows (1) off shock absorber (arrow).
11. If the shock absorber has not been replaced, the sealing rings (arrows) on the piston rod and the shock absorber tube must be replaced.
12. Clean contact surface with a lint-free cloth. [Note: Even slight soiling leads to air spring strut leakages.]
13. Lightly grease the seal with lithium greaseG 052 150 A2.
14. Push retention element onto shock absorber tube.
15. Fit bellows (1) onto shock absorber.
16. Ensure groove of bellows latches into place on shock absorber (arrow). [Note: If the air spring is to be reused and the plunger has slipped out of the external guide, it must be pushed in again by forming an even fold all around the bellows (arrows).]
17. Extend shock absorber line, e.g. with a cable in order to take it through the air spring.
18. Push bellows downwards.
19. Make sure that bump stop (1) is correctly seated in cover (2)(arrow).
20. Fit mounting and secure with a new bolt, counterholding by the hexagonal piece (3).
21. Align air spring so that pressure retention valve (1) is located precisely on the air spring strut's imaginary symmetry axis (arrow).
22. The pressure retention valve (1) must face towards the hole for coupling rod (2). [Note: During alignment, only turn by the plunger in order to avoid damaging the bellows inside the air spring.]
23. Fit cover (3) and secure with bolts (2).
24. Insert grommet (1) in cover (3).
25. Push cable through grommet.
26. Insert cable lug into connector housing.
27. Install air spring strut , but do not yet install air line.
28. Raise air spring strut using engine and gearbox jackV.A.G 1383 A until plunger (1) lies on retention element (arrow).
29. Use removal wedge3409 to push retention element into plunger.
30. Continue to raise air spring strut using engine and gearbox jackV.A.G 1383 A until welded ring on shock absorber tube has disappeared approx. 3 mm into retention plunger (arrow).
31. When lowering (rebound), hold pressure retention valve open by opening valve tappet, e.g. with a 5 mm hexagon wrench, so that air can flow in. [Note: This prevents the bellows from wrinkling.]
32. Push bellows onto air spring.
33. Install wheel and tighten bolts or nuts .
34. Fill air spring strut with the Vehicle diagnosis, testing and information systemVAS 5051B.

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Removing and installing wheel bearing unit up to model year 2007
• Removing and installing vane pump, V6 petrol engine – VW
• Removing and installing front wheel bearing with wheel bearing housing installed
• Removing and installing left flange shaft – VW Phaeton
• Removing and installing alternator, 1.9 l TDI engine with DSG