Volkswagen Phaeton 43-2

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Barnaby Patterson
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1 Стр. 1 из 27 Volkswagen Phaeton 43-2 Self-leveling suspension, servicing Troubleshooting of air spring struts and level control system Condition Verification Possible causes Corrective action Very slow loss of pressure vehicle sits crooked after a longer time period Vehicle sits crooked no leakage Vehicle sits too high, cannot be lowered Observe level over longer time period and identify leakage using commercially available leak-detection spray 1) Perform "Guided Fault Finding" using Vehicle Diagnosis, Testing and Information System VAS ) Check if = vehicle has sufficient ground clearance 2.) Check air lines and line routing Leakage at air spring shock absorber Leakage at air lines Leakage at residual pressure retaining valve Vehicle level sensors faulty Linkage or retainer for Level Control System Sensor is bent Vehicle has bottomed out Air line plugged, pinched or frozen Replace air spring strut front 40-3, Air spring strut removing and rear 42-4, Air spring strut, removing and Air line, servicing 43-2, Air line, servicing Replace air spring strut front 40-3, Air spring strut removing and rear 42-4, Air spring strut, removing and Replace Level Control System Sensor 43-2, Selflevelling suspension system, components and installation locations Pinched air lines, servicing, 43-2, Air line, servicing Frozen and plugged air lines, blowing out with compressed air

2 Стр. 2 из 27 3.) Perform "guided fault finding" using vehicle information system VAS 5051 Exhaust valve or air spring valve malfunctioning 4.) Perform steps 1-3, and if no problems are found up to this point, the residual pressure retaining valve is stuck Residual pressure retaining valve stuck Replace air spring strut front 40-3, Air spring strut removing and rear 42-4, Air spring strut, removing and 5.) Perform "guided fault finding" using vehicle information system VAS 5051 Inspection of electrical system relays, harness connectors, wiring and fuses Vehicle sits crooked and can not be raised or can only be raised very slowly 6.) Identify leakages at accumulator with commercially available leak detection spray 7.) Perform "guided fault finding" using vehicle information system VAS 5051 Pressure accumulator leaking Air line or connectors to accumulator leaking Exhaust valve faulty, leaking or open Replace accumulator Air line, servicing 43-2, Air line, servicing Replace air supply unit 43-2, Air supply unit, removing and 8.) Perform steps 5-7, and if no problems are found up to this point, the air supply unit is faulty Air supply unit faulty Replace air supply unit 43-2, Air supply unit, removing and "Quick" pressure loss Vehicle level is uneven, and when attempting to change vehicle level, air escaping from the faulty air spring is audible Air spring faulty Replace air spring strut front 40-3, Air spring strut removing and rear 42-4, Air spring strut, removing and Air line, servicing 43-2, Air line,

3 Стр. 3 из 27 Air line is torn off servicing Insufficient damping Test drive, and adjust the dampening level. The change must be clearly noticeable. Pay attention to "rumbling noises" when driving over uneven roadways. Dampening Adjustment Valve faulty Strut worn Replace air spring strut, front 40-3, Air spring strut removing and rear 42-4, Air spring strut, removing and Replace air spring strut, front 40-3, Air spring strut removing and rear 42-4, Air spring strut, removing and Clean air line system 2) 1) Perform the following test under these conditions: The vehicle must be cold and can not be moved during test Room temperature must be between C and remain constant The vehicle must be sitting on a level surface - Start engine. - Move vehicle with Front Information Display Control Head Control Module J523 to high and then to normal level. - Switch engine off. - Remove connector from Level Control System Control Module J197 to prevent level control from readjusting.

4 Стр. 4 из 27 - Measure vehicle height at all four wheels. - After 24 hours, measure again vehicle height and compare measurement - a - with first measurement. If the vehicle is sitting crooked, a leak is present at suspension with the greatest difference between the first and second measurement. - Check affected air spring strut and corresponding air line using commercially available leak-detection spray in this order: Air line connections Residual pressure retaining valve Check front air spring strut when installed, and check rear air spring struts when removed from vehicle. 2) If an air spring strut is faulty, it may be possible that oil from the strut is leaking into the air supply system. For problemfree operation of the air spring system, it is recommended that the system be cleaned and additional components be replaced after a repair. - Remove affected line from air spring strut and solenoid valve. - Blow line clean with compressed air several times. To do this, direct compressed air to end of solenoid valve line. - Inspect to see if strut oil has leaked into solenoid valve. If strut oil is found in solenoid valve, it must be replaced. - Check internal line from air supply unit to solenoid valve block. If oil is found in internal line, air supply unit must be

5 Стр. 5 из 27 replaced. Self-levelling suspension system, components and installation locations Air supply unit with solenoid valve block Removing and 43-2, Air supply unit, removing and Location: under spare tire well With motor for compressorlevel control system V66 With level control pump temperature sensor G290

6 Стр. 6 из 27 Level control system control module J197 Location: Behind left rear E- Box Removing and 43-2, Level control system control module J197, removing and Reservoir Location: Left rear wheelhouse Left rear level control system sensor G76 Assembly overview 43-2, Left and right rear level control system sensors G76 / G77, removing and Left rear air spring strut With left rear dampening adjustment valve N338 Left rear wheel acceleration sensor G339 Assembly overview 43-2,

7 Стр. 7 из 27 Left and right rear wheel acceleration sensors G339 / G340, removing and Discontinued as of chassis number: 3D4 to Left Front Body Acceleration Sensor G341 Assembly overview 43-2, Left and right Front Body Acceleration Sensor G341 / G342, removing and Left front wheel acceleration sensor G337 Assembly overview 43-2, Left and right front wheel acceleration sensors G337 / G338, removing and Discontinued as of chassis number: 3D4 to Left front air spring shock strut With left front dampening adjustment valve N336 Left Front Level Control System Sensor G78

8 Стр. 8 из 27 Assembly overview 43-2, Left and right front level control system sensors G78 / G289, removing and Right front wheel acceleration sensor G338 Assembly overview 43-2, Left and right front wheel acceleration sensors G337 / G338, removing and Discontinued as of chassis number: 3D4 to Right Front Level Control Sensor G289 Assembly overview 43-2, Left and right front level control system sensors G78 / G289, removing and Right front air spring shock strut With right front dampening adjustment valve N337 Right Front Body Acceleration Sensor G342

9 Стр. 9 из 27 Assembly overview 43-2, Left and right Front Body Acceleration Sensor G341 / G342, removing and Right rear wheel acceleration sensor G340 Assembly overview 43-2, Left and right rear wheel acceleration sensors G339 / G340, removing and Discontinued as of chassis number: 3D4 to Right rear level control system sensor G77 Assembly overview 43-2, Left and right rear level control system sensors G76 / G77, removing and Rear right air spring shock absorber With right rear dampening adjustment valve N339 Rear Body Acceleration Sensor G343

10 Стр. 10 из 27 Assembly overview 43-2, Rear Body Acceleration Sensor G343, removing and Level control system control module J197, removing and Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Removing - Remove left rear electronic box in luggage compartment Repair Manual, Electrical Equipment, Repair Group 97, Removing and fuse holder, relay carrier, E-boxes and control modules.

Стр. 11 из 27 - Unclip connectors - B, C - at control module. - Bend retaining tabs - 1 - up slightly and remove control module - A - from retainer.

11 Стр. 11 из 27 - Unclip connectors - B, C - at control module. - Bend retaining tabs up slightly and remove control module - A - from retainer. Installing Installation is performed in reverse sequence. - Perform basic setting using Vehicle Diagnosis, Testing and Information System VAS Vehicle Diagnosis, Testing and Information System VAS 5051 Left and right front level control system sensors G78 / G289, removing and Assembly overview for level control system sensor G78 / G289 Level control system sensor G78 / G289 Hex socket head bolt, 5 Nm Hex nut, self-locking 8 Nm

Стр. 12 из 27 Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Removing - Raise vehicle. - Disconnect electrical connection.

12 Стр. 12 из 27 Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Removing - Raise vehicle. - Disconnect electrical connection. - Remove hex socket head bolts and hex nut while counter holding at studs Installing Installation is in reverse sequence of removal. - Perform basic setting using Vehicle Diagnosis, Testing and Information System VAS Vehicle Diagnosis, Testing and Information System VAS 5051 Left and right front wheel acceleration sensors G337 / G338, removing and Assembly Overview: Left and right front wheel acceleration sensors G337 / G338 Air spring strut

Стр. 13 из 27 Hex head bolt, 10 Nm Left and right front wheel acceleration sensors G337 / G338 with retainer Special tools, testers and auxiliary items required Torque wrench V.A.

13 Стр. 13 из 27 Hex head bolt, 10 Nm Left and right front wheel acceleration sensors G337 / G338 with retainer Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Removing - Raise vehicle. - Disconnect electrical connection. - Remove bolts and remove Left and right front wheel acceleration sensors G337 / G338 with retainer. Installing Installation is in reverse sequence of removal. Left and right Front Body Acceleration Sensor G341 / G342, removing and

Стр. 14 из 27 Assembly Overview: Left and right Front Body Acceleration Sensor G341 / G342 Front Body Acceleration Sensor G341 / G342 Hex nut, 9 Nm Special tools, testers and auxiliary items required

14 Стр. 14 из 27 Assembly Overview: Left and right Front Body Acceleration Sensor G341 / G342 Front Body Acceleration Sensor G341 / G342 Hex nut, 9 Nm Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Removing - Raise vehicle. - Disconnect electrical connection. - Remove hex nut and remove Front Body Acceleration Sensor. Installing Installation is in reverse sequence of removal. Left and right rear level control system sensors G76 / G77, removing and Assembly Overview: Left and right rear level control system sensors G76 / G77

15 Стр. 15 из 27 Hex bolt, 10 Nm Hex nut, 10 Nm Rear Level Control System Sensors G76 / G77 Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Removing - Raise vehicle. - Disconnect electrical connection. - Remove hex bolts and hex nuts - 2 -, remove Front Body Acceleration Sensor. Installing Installation is in reverse sequence of removal. - Perform basic setting using Vehicle Diagnosis, Testing and Information System VAS 5051 Vehicle Diagnosis, Testing and Information System VAS Left and right rear wheel acceleration sensors G339 / G340, removing and

16 Стр. 16 из 27 Assembly Overview: Left and right rear wheel acceleration sensors G339 / G340 Rear air spring strut Hex socket head bolt, 10 Nm Left and right rear wheel acceleration sensors G339 / G340 Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Removing - Raise vehicle. - Disconnect electrical connection. - Remove hex bolts and remove Left and right rear wheel acceleration sensors G339 / G340. Installing

17 Стр. 17 из 27 Installation is in reverse sequence of removal. Rear Body Acceleration Sensor G343, removing and Assembly Overview: Rear Body Acceleration Sensor G343 Hex nut, 9 Nm Rear Body Acceleration Sensor G343 Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Removing - Remove right luggage compartment trim Repair Manual, Body Interior, Repair Group 70, Luggage compartment and cargo area trim; Luggage compartment

18 Стр. 18 из 27 trim, removing and on sides. - Disconnect electrical connection. - Remove hex nut and remove Rear Body Acceleration Sensor G343. Installing Installation is in reverse sequence of removal. Air line, servicing Special tools, testers and auxiliary items required Cutting pliers VAS 6228 Faulty air lines do not need to be replaced completely. Partial replacement is possible using a connector. Application air line and connector see Parts Catalog. Note: The repair point must lie within an area protected from water spray, e.g. in interior or between wheel housing liner and wheel housing. The harness connector must be secured to the body with cable ties or a cable guide, and should never be secured to a fuel line or brake line. Select straight line sections for repair area. - Cut air line toward vehicle straight using air hose pliers VAS 6228.

19 Стр. 19 из 27 - Mark - Arrows - end of line in vehicle and on replacement part with a felt-tip pen. Markings serve for checking after repair work is completed. - Route replacement part along original attachment points. - Insert both ends of lines into harness connector until stop. Air line is inserted far enough in connector if first colored mark cannot be seen (the second colored mark remains visible). Air supply unit with solenoid valve block, assembly overview

20 Volkswagen Technical Site: огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi Стр. 20 из 27 Air supply unit With motor for compressorlevel control system V66 With level control pump temperature sensor G290 Installed in spare wheel well from vehicle underside Removing and 43-2, Air supply unit, removing and Muffler Spring clamp Intake hose Rubber bushing Air supply unit fasteners

21 Стр. 21 из 27 included in kit Rubber bushing Air supply unit fasteners included in kit Coil spring Air supply unit fasteners included in kit One coil spring is packaged separately and must be installed across from the solenoid valve Metal sleeve Air supply unit fasteners included in kit Bolt 9 Nm Air supply unit fasteners included in kit Air line 5 Nm Observe arrangement of lines at solenoid valve 43-2, Line arrangement on solenoid valve Bolt 10 Nm Solenoid valve block Removing and 43-2, Solenoid valve, removing and Air line 5 Nm

22 Стр. 22 из 27 Between solenoid valve block and air supply unit Air supply unit, removing and Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Removing - Raise vehicle. - Remove plastic cover below spare wheel well. - Disconnect connectors and Remove air lines - arrows -. - Protect air lines from dirt.

23 Стр. 23 из 27 - Remove hex bolts and remove air supply unit from spare wheel well. Installing Installation is in reverse order of removal, note the following: - Insert air supply unit in spare wheel well. - Install hex bolts and tighten. - Install air lines to solenoid valve - A - and tighten. Tightening torque Plastic cover to spare wheel well Air lines to solenoid valve block Air supply unit to spare wheel well 2 Nm 5 Nm 9 Nm Line arrangement on solenoid valve

Стр. 24 из 27 The lines - 1 to 6 - are indicated by color: - 1 - Blue, right rear air spring strut - 2 - Green, right front air spring strut - 3 - Red, left front air spring strut - 4 - Black, left

24 Стр. 24 из 27 The lines - 1 to 6 - are indicated by color: Blue, right rear air spring strut Green, right front air spring strut Red, left front air spring strut Black, left rear air spring strut Black, (approx. 150 mm long) to compressor Yellow, accumulator - Connect electrical connectors and Check basic setting of self-levelling suspension 43-2, Self-levelling suspension, basic setting. Solenoid valve, removing and Special tools, testers and auxiliary items required

25 Стр. 25 из 27 Torque wrench V.A.G 1331 Removing - Raise vehicle. - Remove plastic cover below spare wheel well. - Disconnect air lines - arrows -. - Protect air lines from dirt. - Disconnect connectors and Remove air line - arrow - from compressor. - Disconnect connector

26 Стр. 26 из 27 - Remove hex bolts and remove solenoid valve - A -. Installing Installation is in reverse order of removal, note the following: - Insert solenoid valve and push in. - Install air lines to solenoid valve - A -. Line arrangement on solenoid valve arrangement on solenoid valve. 43-2, Line Tightening torques Plastic cover to spare wheel well Air lines to solenoid valve block Solenoid valve to air supply unit 2 Nm 5 Nm 10 Nm Self-levelling suspension, basic setting - Check basic setting of self-levelling suspension Vehicle Diagnosis, Testing and Information System VAS Connect Vehicle Diagnosis, Measurement and Information System VAS 5051 and continue switching until "Functions/Component selection" is shown. Then - Press "Suspension, Wheels, Steering". - Press "Level control system". - Press "01 - On Board Diagnostic (OBD) capable systems". - Press "Functions". - Press "Basic setting". The vehicle diagnosis, testing, and information system VAS

27 Стр. 27 из now displays the specified values for the basic setting. - Measure actual ride height of vehicle 43-2, Ride height, measuring. - If you determine a deviation from the specified values, you must input actual value in Level Control System Control Module with help of Vehicle Diagnosis, Measurement and Information System VAS The self-levelling suspension control module "calculates" the entered values and regulates the vehicle to the level for basic setting. Ride height, measuring - Measure ride height vertically from lower edge of fender to center of wheel.

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