Self Leveling Suspension Audi A6 C5

Electrical/electronic component locations

Note. The following list refers to items in (Scheme 225).

1. Air supply unit The air supply unit consists of the following components: Level Control System Control Module -J197- Relay for compressor level control system -J403- Motor for compressor-level control system - V66- Solenoid for level control system -N111- Left Rear Suspension Strut Valve -N150- Right Rear Suspension Strut Valve -N151- Multi-pin connectors with assigned contacts If control module is replaced, select "Replacement" function for appropriate control module in "Guided fault-finding". Vehicle diagnostic, testing and information system VAS 5051 is to be used for this purpose.
2. Left rear air spring
3. Level Control System Sensor (ESP) -G84- Checked by On Board Diagnostic (OBD)
4. Right rear air spring

Scheme 225

Air supply unit

1. VOSS connections (air connection)
2. Multi-pin connector In the event of malfunctions, check connector for corrosion. Plug in 20-pin wiring harness connector on control module in air supply unit (connector must be felt to engage).
3. Noise insulation box
4. Two-pin connector (power supply forMotor for compressor-level control system -V66-) Plug in two-pin round connector for compressor supply (connector must be felt to engage).

Scheme 226

Malfunction indication via indicator lamp for level control system -K134

If the indicator lamp for level control system -K134- does not go out after the ignition is turned on and the test sequence is complete (about 2 sec.), it could be caused by the following errors

1. The voltage is under 10 V.
2. If there is an error in the level control system, check DTC memory. See «ON BOARD DIAGNOSTIC (OBD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#on-board-diagnostic-obd-suspension-tire-pressure-monitoring) .
3. The instrument cluster is faulty.

Scheme 227

Noise insulation box, structure

1. Level control system control module -J197
2. Motor for compressor-level control system-V66
3. Double plug connection
4. Relay for compressor level control system -J403
5. Multiway plug connection on back of level control system control module -J197
6. Twelve-way plug connection on level control system control module -J197

The valves are under gray foam.

Scheme 228

Air supply unit, assembly overview

Tightening torque for all air lines on the Audi A6 is 2 Nm (9 in. lb).

Note. The following list refers to items in (Scheme 229).

1. Clip
2. Air line See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
3. Connection piece
4. Hex nut M 6
5. Sheet-metal screw
6. Sheet-metal piece For centering valve unit
7. Rubber seal
8. Housing cover
9. Top foam piece
10. Valve unit
11. Air compressor
12. Gasket Always replace
13. Bottom foam piece
14. Unit housing
15. Hex bolt, 10 Nm When reinstalling use safeguard material D 000 600 A2
16. Bonded fiber mat Only A6 Avant Preformed bonded fiber mat is glued onto bottom shell of unit
17. Air line From compressor to solenoid valve See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .

Scheme 229

Special tools and equipment

1. T 40002 Level regulating tool

Test requirements

1. Vehicle in unladen state (at curb-weight)
2. Proper tire pressures (refer to inflation pressure label on vehicle).
3. Correct tread depth (set 1 mm less for each 1 mm of wear)
4. Wait until control procedure has been completed (observe compressor run)
5. Measure height of vehicle at relevant points (production intake points) relative to ground

Note test requirements when measuring axle in vehicles with level control (1BG) .

Basic setting must be performed if the level control sensor, the entire unit or the control module is replaced.

1. Set special tool T40002 to appropriate length. (Scheme 231) See «APPLICATION OF GROUND DISTANCE DIMENSIONS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__application-of-ground-clearances-setting-dimensions).

Scheme 230

Application of ground clearances (setting dimensions) for suspension

APPLICATION OF GROUND CLEARANCES (SETTING DIMENSIONS) FOR SUSPENSION

Scheme 231

Scheme 232

1. Raise vehicle (rear axle suspension fully extended).
2. Insert special tool T40002 into production mounts at rear (arrow).
3. Turn both knurled screws such that rubber bead in mount is compressed and special tool remains in position.
4. Lower vehicle NOTE: Vehicle must be standing on a level surface. Only on AWD models
5. Move vehicle forward and backward approx. 3 feet and bounce rear of vehicle to eliminate wind-up of rear axle tires.
6. Refer to table to check clearance dimension (specified jacking points/shop floor) and repeat basic setting if necessary in the event of deviation. Make allowance for determined deviation at special tool T40002. If vehicle is too low, increase setting dimension (refer to «APPLICATION OF GROUND CLEARANCES (SETTING DIMENSIONS) FOR SUSPENSION»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) table) by this amount.

Basic setting must be performed if: control module, angle sensor or entire unit is replaced.

Setting is performed for drive position.

1. Voltage supply and fuses for the relevant systems OK.
2. Scan tool VAG 1551/1552 or VAS 5051 connected See «ON BOARD DIAGNOSTIC (OBD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#on-board-diagnostic-obd-suspension-tire-pressure-monitoring) .
3. Use special tool T 40002

Procedure

1. Basic setting is carried out via function "11 - Login".
2. Inserting of special tool T 40002

Perform Function "11 - Login"

Display

Scheme 233

1. Press buttons 1 and 1.

Display

Scheme 234

1. Confirm input with -Q- button.

Indicated on display

Scheme 235

1. Press buttons 3, 1, 5, 6 and 4.

Indicated on display

Scheme 236

1. Confirm input with -Q- buttons.

Indicated on display

Scheme 237

1. Press buttons 0 and 4.

Display

Scheme 238

1. Confirm input with -Q- button.

Indicated on display

Scheme 239

1. Press buttons 0, 0, and 1.

Indicated on display

Scheme 240

1. Confirm input with -Q- button.

Indicated on display

Scheme 241

1. Press --> button.

The system vents air and lowers the rear down to special tool T 40002.

At the same time, the control module forgets the old control position. There is an entry into the DTC memory (DTC 01437).

After completion of basic setting, the following appears in display

Scheme 242

1. Now press button 3.

Indicated on display

Scheme 243

1. Press --> button.
2. The basic setting procedure is now completed.
3. Erase DTC memory. See «ON BOARD DIAGNOSTIC (OBD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#on-board-diagnostic-obd-suspension-tire-pressure-monitoring) .

2-wheel air suspension, charging system

If the shock absorber, air spring or air line is replaced (or air pressure released) system must be re-charged.

Vehicle must not stand on wheels until the system has been filled (if a repair was performed on the spring system beforehand), otherwise the air spring may be damaged!

1. Raise vehicle (fully extend rear axle suspension).
2. Make sure there are no folds in air springs.
3. Use final control diagnosis function to charge air springs. See «ON BOARD DIAGNOSTIC (OBD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#on-board-diagnostic-obd-suspension-tire-pressure-monitoring) .
4. Check that there are no leaks in the system.
5. Make sure the installed air springs/suspension struts are correctly seated.
6. Lower vehicle.
7. Check level, set if necessary. See «APPLICATION OF GROUND CLEARANCES (SETTING DIMENSIONS) FOR SUSPENSION»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__application-of-ground-clearances-setting-dimensions) .

Functional test

Switch on ignition, check DTC memory, and erase DTC memory if necessary.

See ON BOARD DIAGNOSTIC (OBD) .

System errors are indicated by the yellow check light in the tachometer dial lighting up and staying lit.

Then, check the operation of the system by loading the rear axle (for example by opening the trunk and sitting in it).

After no more than 10 seconds the system should begin raising/pumping up the rear axle to equalize the compression caused by the loading.

Maximum pumping time is 30 seconds

If the distance dimension falls more than 6 mm within 24 h, then the system has a leak and has to be checked.

The level control system monitors how long the compressor is turned on to avoid possible overheating or excessive battery discharge. If no switch-on occurs despite a requirement for it, then you can proceed as follows

1. Wait approx. 6 minutes. If there is an excess temperature, then after this period of time (6 minutes) at the latest a switch-on time of about 15 seconds is possible.
2. Starting the engine allows normal switch-on once again, without regard to battery condition.

Air unit mount, assembly overiew

Tightening torque for all air lines on Audi A6: 2 Nm

Note. The following list refers to items in (Scheme 245).

1. Air supply unit
2. Rubber bushing Kidney-shaped recess faces upwards
3. Air supply unit holder See «INSTALLING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__installing) .
4. Self-locking hexnut
5. Rubber grommet
6. Hexbolt, 25 Nm
7. Holder support section 1
8. Hex nut, 25 Nm
9. Speed nut M 8 x 25 x 17
10. Holder support section 2

Scheme 244

Removing

1. Removing Switch off ignition. Disconnect battery ground (GND) strap. Prior to removal of air supply unit with mount, tool kit, navigation system or CD changer must be taken out. See «RADIO SYSTEMS»(/audi/a6/c5-1997-2001/remont/communication-devices/#radio-telephone-navigation-trip-computer). Unplug black connector -A-. (Scheme 245) Unplug red connector -B-. Unscrew air connections -C-. When pulling out compressed air lines, take care not to alter position of cutting rings at front of line, as otherwise leaks may occur on re-installation. Unscrew hex nuts, Item -8-. (Scheme 245)

Scheme 245

1. Instead of bonded joint, additional attachment points are required on installing holder -3-. (Scheme 246)
2. Remove dirt (wax etc.) on inside holder support area of body.
3. Remove grommet in bottom part of unit holder.
4. Insert unit holder in body and screw to wheel housing flange and longitudinal member.
5. Make three 8.5 mm diameter holes in unit holder and body at marked locations (holder).
6. Remove unit holder and deburr holes.
7. Remove corrosion protection (PVC) in nut on outside of body.
8. Insert unit holder and screw on as follows.

Tightening sequence

Scheme 246

1. Holder to longitudinal member -A-. (Scheme 247)
2. Holder to wheel housing flange -B
3. 1- Hex bolt, 25 Nm. (Scheme 247)
4. 2- Hex flange nut
5. 3- Speed nut
6. Insert rubber grommet.
7. Seal attaching points on outside of body (black Terolan).
8. Insert unit with support sections -1- and -2- in unit holder and screw on. Pay attention to installation position of rubber bushings. See «AIR UNIT MOUNT, ASSEMBLY OVERIEW»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__air-unit-mount-assembly-overiew), Item 2.
9. Listen to make sure connectors engage properly.
10. Take care not to alter position of cutting rings on compressed air lines when inserting valves, as otherwise screw connection may leak.

Perform remaining installation operations in reverse order.

Air line routing (front wheel drive), assembly overview

Tightening torque for all air lines on the Audi A6 is 2 Nm (9 in. lb).

Note. The following list refers to items in (Scheme 248).

1. Clip
2. Air line Air supply unit to air spring Clip air lines into markings provided for them. See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
3. Air supply unit Removing and installing, see «AIR UNIT MOUNT, ASSEMBLY OVERIEW»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__air-unit-mount-assembly-overiew)
4. Shock absorber
5. Connection piece See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
6. Clip clip onto shock absorber
7. Air line Air supply unit to air spring See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
8. Clip Clip onto parking brake cable
9. Air line Air spring to shock absorber See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
10. Stone impact protection plate
11. Cable ties
12. Connection piece See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .

Scheme 247

Scheme 248

Make sure correct color markings -A- go with associated position markings of attachment clips or grommets -B

Connector system

1. The lines are correctly plugged together when only one of the markings (arrow) is visible.

Scheme 249

Note. It is not permissible to shorten the lines. The lines are removed by removing the union screw connection. Remove protective transportation caps of air lines only after laying them, immediately before plugging them together.

Air-spring shock absorbers (front wheel drive), assembly overview

Tightening torque for all air lines on the Audi A6 is 2 Nm (9 in. lb).

Note. The following list refers to items in (Scheme 251).

1. Sealing ring
2. Air spring Removing and installing, see «AIR SPRINGS, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension)
3. Connection piece See note under «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) and «CONNECTOR SYSTEM»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__connector-system).
4. Combi bolt, 5 Nm
5. Stone impact protection plate
6. Spring support
7. Protective sleeve
8. Stop buffer
9. Clip
10. Air line Clip air lines into markings provided for them. See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension).
11. Connection piece See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension).
12. Shock absorber
13. Hex bolt, 45 Nm
14. Installation cap Only for factory installation, not used for repairs.
15. Self-locking hex nut, 25 Nm Loosening and tightening (Scheme 252)Always replace after disassembly
16. Top shock absorber mount

Scheme 250

Loosening and tightening screw connection for shock absorber mount

1. Remove installation cap ( (Scheme 251), item no. 14).

Scheme 251

1. Unscrew combi bolts -1- and carefully fold down skid plate. (Scheme 253)
2. Carefully open and remove air connections -3-.
3. Remove air spring

Scheme 252

Installing

Note. System must be filled before vehicle rests on wheels again. See 2-WHEEL AIR SUSPENSION, CHARGING SYSTEM . When filling, vehicle must be unladen (at curb-weight). For positioning air springs when filling. See 2-WHEEL AIR SUSPENSION, CHARGING SYSTEM .

Installation is reverse of removal.

1. VAG1383 A engine/transmission jack with universal transmission holder VAG1359/2

Scheme 253

Scheme 254

1. Carefully open and remove air connections -4-.

Note. To remove and install spring cylinder, use engine/transmission jackVAG1383 A with holder 1359/2.

Scheme 255

1. Remove bolt -2- on left and lower engine/transmission jack. (Scheme 256)
2. Unscrew bolt -1- and remove shock absorber.
3. Pull down rear axle, by second mechanic if necessary, and remove shock absorber.

Installation is reverse of removal.

1. REPLACE all bolts and nuts.
2. Insert shock absorber in body and tighten to 45 Nm.
3. Install bolt below, shock absorber to rear axle.

Scheme 256

1. Self-locking nut
2. Hex bolt
3. Shock absorber

After installing air spring or shock absorber system must be filled.

Filling system, see 2-WHEEL AIR SUSPENSION, CHARGING SYSTEM

Note. System must be filled before vehicle rests on wheels!

Screw connection between shock absorber and rear axle must be tightened when vehicle is standing on its wheels!

1. Tighten shock absorber to rear axle to 50 Nm plus additional 90 ° turn.

Level sensor (front wheel drive), assembly overview

1. Hex-nut, tighten to 3 Nm. See «LEVEL SENSOR (FRONT WHEEL DRIVE), REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
2. Level sensor
3. Coupling link
4. Level sensor bracket
5. Double hex bolt, 25 Nm
6. Hex-nut, tighten to 10 Nm.
7. Socket-head bolt,4 Nm
8. Hex-nut, tighten to 5 Nm.
9. Cable ties
10. Hex-nut, tighten to 10 Nm.

Scheme 257

1. Switch off ignition.
2. Disconnect Ground (GND) strap from battery
3. Unplug connection -2- from level sensor. (Scheme 259)
4. Remove cable ties
5. Remove hex nuts 1, 4, and 5.
6. Remove level sensor.

Be careful not to turn sensor crank by 180°, or else basic adjustment must be made again.

Scheme 258

See ON BOARD DIAGNOSTIC (OBD) .

Note. When installing linkage at level sensor, use an 8 mm opened wrench with dimension -A-, to avoid damaging seal. (Scheme 260)

Dimension -A-: 4 mm

When installing level sensor, make sure that sensor crank and linkage are in correct orientation to one another.

Scheme 259

Note. Linkage must be vertical. Sensor crank (arm) must point backward and downward.

Rest of installation is reverse of removal.

Air line routing (all wheel drive), assembly overview

Tightening torque for all air lines on the Audi A6 is 2 Nm (9 in. lb).

Note. The following list refers to items in (Scheme 261).

1. Clip
2. Air line Clip the air lines into markings provided for them. See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
3. Connection piece See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
4. Hex nut M 6
5. Air supply unit Removing and installing, see «AIR UNIT MOUNT, ASSEMBLY OVERIEW»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__air-unit-mount-assembly-overiew)
6. Hex bolt, 10 Nm
7. Air spring
8. Shock absorber
9. Clip
10. Left sensor bracket Removing and installing, see «AIR LINE FROM SENSOR TO AIR SPRING SHOCK ABSORBER»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__air-line-from-sensor-to-air)
11. Hex-nut, tighten to 10 Nm.
12. Bracket Removing and installing, see «AIR LINE FROM SENSOR TO AIR SPRING SHOCK ABSORBER»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__air-line-from-sensor-to-air)
13. Hex-nut, tighten to 10 Nm.
14. Grommet
15. Cable ties Left 1x Right 3x

Scheme 260

Air line from sensor to air spring shock absorber

1. Left sensor bracket
2. Bracket
3. Hex nut, 10 Nm

Scheme 261

Note. Air lines are color-coded: Left side black; Right side blue.

Air spring shock absorbers (all wheel drive), assembly overview

Tightening torque for all air lines on the Audi A6 is 2 Nm (9 in. lb).

Note. The following list refers to items in (Scheme 263).

1. Self-locking hex nut, 27 Nm Always replace after disassembly First remove air compressor plugs
2. Air spring Installing, «INSTALLATION OF AIR STRUT»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__installation-of-air-strut)
3. Shock absorber
4. Clip
5. Self-locking nut, tighten to 70 Nm plus additional 90 ° turn Always replace after disassembly
6. Washer
7. Air spring shock absorbers
8. Hex bolt M12 x 1.5 x 95 Always replace after disassembly
9. Connection piece See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
10. Air line Clip the air lines into markings provided for them. See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
11. Connection piece See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
12. Hex bolt, 45 Nm

Scheme 262

Installation of air strut

Bayonet - connection must be absolutely clean.

1. Coat rubber sealing rings -1- and -2- with lithium - grease G 052 150 A2.
2. Close bayonet - connection by simultaneous pressing and turning.

Scheme 263

1. Remove wheels.
2. Remove both attachment screws carrier / lower control arm (see item E)

1. Hex bolt
2. Parking brake cable
3. Bracket for parking brake cable
4. Control arm

Scheme 264

Scheme 265

Scheme 266

Scheme 267

Scheme 268

1. Disconnect parking brake cables from brake calipers.
2. Remove bolt -A- on both sides. (Scheme 267)
3. Disconnect parking brake cable -B- from bracket -C-.
4. Push catching tabs -A- together and push parking brake cable -2- out of control arm -1-. NOTE: Do not pull on parking brake cable, or adjustment of parking brake will change!
5. Unclip wire for wheel speed sensor from axle beam. 3 - Attachment point on axle beam. (Scheme 269)
6. Unscrew control arm from shock absorber. (Scheme 270) Control arm Parking brake cable Bolt for shock absorber Holding clip for parking brake cable

Scheme 269

1. Unscrew hex bolts (arrows) for shock absorber from body.

Scheme 270

After air spring shock absorbers are removed or installed system has to be refilled.

Filling system, see 2-WHEEL AIR SUSPENSION, CHARGING SYSTEM

Bonded rubber bushings can only be turned to a limited extent. The bolted connections should therefore only be tightened when the vehicle is standing on the ground.

Otherwise, the rubber bushing will be stressed and have a shortened service life.

Tightening torques

TORQUE SPECIFICATIONS: CONTROL ARM & SHOCK ABSORBER

Note. After installation is complete, check setting of parking brake! This might need adjustment.

See PARKING BRAKE .

Level sensor (all wheel drive), assembly overview

Note. The following list refers to items in (Scheme 272).

1. Coupling link
2. Level sensor
3. Level sensor bracket
4. Socket-head bolt, 4 Nm
5. Washer
6. Self-locking hex nut, 40 Nm
7. Hex-nut, tighten to 3 Nm. See «LEVEL SENSOR (FRONT WHEEL DRIVE), REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
8. Hex nut, tighten to 3 Nm. See «LEVEL SENSOR (FRONT WHEEL DRIVE), REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
9. Stabilizer bar
10. Combi bolt, 10 Nm
11. Clamp
12. Lever

Scheme 271

1. Switch off ignition.
2. Disconnect Ground (GND) strap from battery.
3. Unplug connection -1- from level sensor. (Scheme 273)
4. Remove hex bolt -3-.
5. Remove hex nut -4-.

Be careful not to turn sensor crank by 180 °, or else basic adjustment must be made again.

See ON BOARD DIAGNOSTIC (OBD) .

Scheme 272

Note. When installing linkage pos. -1- at level sensor, use an 8 mm open-end wrench with dimension -A-, to avoid damaging seal. (Scheme 274)

1. Dimension -A-: 4 mm

Scheme 273

Note. Make sure that pins at bracket, item no. 3 (see arrow), engage in auxiliary frame. See LEVEL SENSOR (ALL WHEEL DRIVE), ASSEMBLY OVERVIEW . Coupling must be vertical. Sensor crank (arm) must point backward and downward. Make sure that bracket and clamp are screwed to flat part of the stabilizer bar.

Rest of installation is reverse of removal.

Scheme 274

1. Perform system venting of suspension strut. See «SYSTEM VENTING (ALLROAD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__system-venting-allroad).
2. Deactivate level control system. See «DEACTIVATING/ACTIVATING JACK MODE FOR RIDE HEIGHT SYSTEM (ALLROAD)»(/audi/a6/c5-1997-2001/remont/wheel-alignment/#specifications-procedures).
3. Remove wheels.
4. Secure brake disc using a wheel bolt.
5. Remove cover plenum chamber / battery NOTE: In order not to damage joints of lower control arms, it is necessary to use engine/transmission jack VAG1383-A, for example, to brace against too strong rebound.
6. Loosen connection of air hose at suspension strut only far enough, so that air escapes.
7. After pressure in suspension strut / air hose has completely escaped, remove air hose by loosening threaded connection at suspension strut. (Scheme 275)
8. Remove level sensor at track control link.

Note installation position

Note. Observe level control system/automatic vertical headlight aim control. (Scheme 276)

Scheme 275

Scheme 276

Scheme 277

1. Remove bolts -2- (Scheme 277) Tightening torque: 45 Nm and then tighten another 55 °.
2. Remove bolt (arrow). (Scheme 278) Tightening torque: 45 Nm and then tighten another 55 °.
3. Protect steering gear boot from damage.

(Scheme 279) shows steering gear disassembled, to illustrate it more clearly.

Scheme 278

If you wish to order protective sleeve -1-, its part number is 893 512 137.

1. Protective sleeve -1- must have a strip having dimension -A- from 20 to 25 mm cut out of it. (Scheme 279)
2. Carefully deburr cut edges.
3. Push protective sleeve over steering gear boot.
4. The open, slit should face downward.
5. Unscrew nut -1-.

1. Remove hex bolt and lift out control arm -2-. (Scheme 280)
2. Swing away wheel bearing housing toward side, in direction of (arrow).

Otherwise axle adjustment must be checked!

Scheme 279

To unscrew hex bolt from suspension strut/track control link, you must detach guide link from wheel bearing housing.

Note. Protect CV boot from damage, for example, place a leather cloth in between. For safety reasons, put collar nut back on joint bolt of track control link with about 4 turns, so that it is flush. Be sure that both lever arms are parallel to each other during greatest applied pressure, adjust if necessary.

Use 4 mm socket wrench to hold joint bolt, if necessary.

Scheme 280

1. Unscrew nut from joint bolt of guide link, then press off joint bolt.

Be careful not to damage CV boot in the process!

Scheme 281

1. Unscrew bolt -2-, suspension strut/track control link. (Scheme 282)
2. Pull suspension strut down and out.
3. Only hold suspension strut at mounting bracket and at strut tube as shown in illustration.

Note. Be careful not to damage CV boot when removing suspension strut.

1. Mark position of shock absorber - mounting bracket

Scheme 282

Only hold suspension strut at mounting bracket and at strut tube.

1. Position mounting bracket according to mark.
2. Secure suspension strut to chassis using mounting bracket.

Bolt tightening sequence, as numbered in (Scheme 284), is mandatory.

Tightening torque: 45 Nm and then tighten another 55 °.

Scheme 283

Note. Always use new mounting bracket!

1. Bolt suspension strut together with track control link. Tightening torque: 90 Nm
2. Bonded rubber bushings can only be turned to a limited extent. The suspension strut/track control link bolt connection should therefore only be tightened when the vehicle is standing on the ground.

Note. Charge system before vehicle is allowed to stand on its wheels.

Note. Remove any adhesive remaining on thread of joint bolt.

Scheme 284

1. Tighten new nuts to 100 Nm. Use 4 mm socket wrench to hold joint bolt, if necessary.
2. Insert upper control arm in wheel bearing housing and tighten new nuts -6- to 40 Nm. (Scheme 285)
3. Press upper control arm down as far as possible when tightening!
4. Secure Voss air connection 2 Nm
5. Position chafe protection -7- properly.
6. Screw on new bolts for suspension strut and tighten to 20 Nm. Be careful not to damage surface of brake lines!
7. Secure bracket for level control at track control link
8. Put rubber grommets in plenum chamber.
9. Filling air spring. See «SYSTEM FILLING (ALLROAD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__system-filling-allroad).

Note. System must be filled before vehicle rests on wheels!

1. Mount wheel and tighten to 120 Nm. Observe assembly notes. See «WHEEL REPLACEMENT/WHEEL INSTALLATION, ASSEMBLY NOTES»(/audi/a6/c5-1997-2001/remont/warning-system/#wheels-tires) .
2. Perform basic setting of level control. See «BASIC SETTING (ALLROAD), PERFORMING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__basic-setting-allroad-performing) .

Mounting bracket (allroad suspension), removing and installing

1. Remove suspension strut first. See «FRONT SUSPENSION STRUT, REMOVING AND INSTALLING (ALLROAD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
2. Clamp fork area of suspension strut in vise (use protective pads).
3. Mark position of shock absorber - air spring piston - mounting bracket.
4. Remove bolts (6x, -arrows-) Tightening torque: 23 Nm

Scheme 285

Always use new bolts and a new sealing ring!

1. Lubricate NEW, upper sealing ring. See «AIR SPRINGS, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .

1. Remove suspension strut first. See «FRONT SUSPENSION STRUT, REMOVING AND INSTALLING (ALLROAD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
2. Remove bolts -1- (2x).

Scheme 286

1. Place a straight object -2-, for example, a ruler, on mounting bracket (Scheme 287) Dimension -A- = 65 mm + 2 mm. Dimension -B- = 49.5 mm + 2 mm. Measured from the straight edge to the highest point at control arm.
2. Replace all bolts and nuts.
3. Tighten hex bolts -1- of the two control arms to 50 Nm, then turn another 90°.

Scheme 287

1. Remove suspension strut first. See «FRONT SUSPENSION STRUT, REMOVING AND INSTALLING (ALLROAD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension).
2. Mark position of shock absorber - air spring piston - mounting bracket.
3. Remove mounting bracket. See «MOUNTING BRACKET (ALLROAD SUSPENSION), REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__mounting-bracket-allroad-suspension-removing-and).
4. Unscrew nut -1-. (Scheme 289)
5. Use NEW nut. Tightening torque: 60 Nm
6. Remove air-spring boot upward.

Scheme 288

Installation is reverse of removal.

1. Coat rubber sealing ring -2- with G 052 150 A2 lithium lubricant.
2. Align shock absorber - air spring piston - mounting bracket. according to mark.
3. Make sure auxiliary spring is properly seated in cover

Scheme 289

Lower rubber sealing ring must be dry and dust-free.

Scheme 290

Scheme 291

1. Lower rubber sealing ring must be placed on the second step of the strut tube from the top.
2. Place air-spring on rubber sealing ring and press downward. NOTE: Air spring must not bend when pressing down! With sliding motion of piston, rubber sealing ring rolls up to the 3rd offset on which the spring supports itself and seals.
3. Dimension -A- between the center bore for air-spring/control arm bolts and the lowerend of air-spring must be less than 262mm before filling.
4. Check lateral movement of piston. It must not be possible to twist air-spring on strut.
5. Install mounting bracket. See «MOUNTING BRACKET (ALLROAD SUSPENSION), REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__mounting-bracket-allroad-suspension-removing-and).
6. Install suspension strut. See «INSTALLING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension).
7. Hold suspension strut only at mounting bracket and strut tube (Scheme 293)

Scheme 292

Rear air spring shock absorbers (Allroad), assembly overview

Note. The following list refers to items in (Scheme 294).

1. Self-locking hex nut, 27 Nm Always replace after disassembly first remove air compressor plugs
2. Air spring Installation, see «INSTALLATION OF AIR STRUT»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension)
3. Shock absorber
4. Clip
5. Selflocking nut, tighten to 70 Nm plus additional 90 turn Always replace after disassembly
6. Washer
7. Air spring shock absorbers
8. Hex bolt M 12 x 1.5 x 95 Always replace after disassembly
9. Connection piece See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
10. Air line Clip the air lines into markings provided for them. See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
11. Connection piece See «MARKINGS»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) .
12. Hex bolt, 45 Nm

Scheme 293

Bayonet connection must be absolutely clean.

1. Coat rubber sealing rings -1- and -2- with G 052 150 A2 lithium lubricant.
2. Close bayonet connection by simultaneous pressing and turning.

Scheme 294

Shock absorbers/springs, removing and installing

Removing and installing is the same as for 2-WHEEL AIR SUSPENSION .

1. Venting system, see «SYSTEM VENTING (ALLROAD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__system-venting-allroad)

1. Filling air spring. See «SYSTEM FILLING (ALLROAD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__system-filling-allroad) .

Note. Vehicle must not stand on its wheels before the filling has been performed!

Component locations

Note. The following list refers to items in (Scheme 296).

1. Right front air strut
2. Operating unit
3. Right rear air strut
4. Right rear level control system sensor -G77
5. Control module Removing, see «LEVEL CONTROL SYSTEM CONTROL MODULE -J197- (ALLROAD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension) Installing, see «LEVEL CONTROL SYSTEM CONTROL MODULE -J197- (ALLROAD), INSTALLING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension)
6. Pressure reservoir Assembly overview, see «PRESSURE RESERVOIR, ASSEMBLY OVERVIEW»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__pressure-reservoir-assembly-overview)
7. Left rear level control system sensor -G76
8. Left rear air strut
9. Air supply unit with: Compressor Solenoid for level control system -N111- Lateral check-valves Level Control Pump Temperature Sensor -G290- Level Control Pressure Sensor-G291- Auxiliary noise insulation Component overview, see «COMPRESSOR (ALLROAD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension)
10. Electric/pneumatic lines
11. Left front air strut
12. Left front level control system sensor -G78
13. Right front level control system sensor -G289

Scheme 295

Pressure reservoir, assembly overview

Note. The following list refers to items in (Scheme 297).

1. Voss -connector system Tightening torque: 2Nm
2. Hex nut Tightening torque: 23Nm
3. Pressure reservoir A system venting of the pressure reservoir must be performed before removing pressure reservoir. See «SYSTEM VENTING (ALLROAD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__system-venting-allroad) .
4. Muffler
5. Hex nuts(3x) Tightening torque: 3Nm
6. Bracket
7. Combination bolt Tightening torque: 23Nm

Scheme 296

1. Remove nuts -5- Tightening torque: 10 Nm
2. Remove nut -4- Tightening torque: 10 Nm

Scheme 297

Installation is reverse of removal.

If level sensor is replaced or a connection is opened, basic setting must be performed. See BASIC SETTING (ALLROAD), PERFORMING .

Basic setting (Allroad), performing

Basic setting must be performed if the level control sensor, the entire unit or the control module is replaced.

Scheme 298

1. Perform basic setting. See «ON BOARD DIAGNOSTIC (OBD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#on-board-diagnostic-obd-suspension-tire-pressure-monitoring). Determining height dimension: -x- The height dimension -x- is the value in mm between wheel center and lower edge of fender. (Scheme 299)
2. Measure rim diameter. Measure value determines dimension: -a-. (Scheme 299)
3. Measure vertically from upper edge of rim to lower edge of fender Measure value determines dimension: -b- Height dimension -x- results from: -x- = -a- / 2 + -b
4. After performing basic setting, check whether height dimension -x- = 402mm + 5 mm. If this is not the case, repeat basic setting. (Scheme 300)
5. After performing basic setting, check whether height difference between left and right side is not larger than + 4 mm. If this is not the case, repeat basic setting.

Scheme 299

System filling (Allroad)

Vehicle must not be standing on its wheels during filling of the system (if a repair at the spring system was performed before), otherwise the air spring will be damaged!

It is possible to perform filling of the air spring system without having to loosen mechanical connections.

System filling via On Board Diagnostic (OBD) must only be performed with the vehicle standing!

Note. The air spring system (pressure reservoir, air springs, pressurized air lines) can be filled using the VAG tester. For this, the valid limit values are: Air spring 9 bar /pressure reservoir 13 bar. System filling is performed in stages. (air springs, front /air springs, rear / pressure reservoir) Filling is only possible after manually switching off the regulation. Switching off and on of the regulation is performed with the VAG tester (Fct. > 10, channel 10) or via manually pressing button for up and down (press button twice > 5 seconds). Time frame for filling is limited to 65 seconds. However, it is possible to perform the function several times in sequence to accumulate a longer filling time. It is possible to perform a filling procedure in stages using the up and down arrow buttons of the VAG tester.(buttons 1/3 of VAG1551 tester have the additional assignment uparrow - button / downarrow - button)

Equipment

1. Data is transmitted between the control module and the VAS 5051 tester or VAG 1551 Scan Tool (ST) via operating mode "Rapid Data Transfer".
2. DTC memory is designed for permanent memory and is therefore not dependent on voltage supply.

1. Battery voltage at least 11 V
2. Ground (GND) connections at engine and transmission OK
3. Engine off
4. Automatic in position "P" or "N"

Scheme 300

1. Connect VAS 5051 tester with VAS 5051/1 diagnostic wire with the ignition switched off. Alternately, VAG 1551 Scan Tool (ST) can also be attached using VAG 1551/3A adapter.

Note. The following description only explains implementation of On Board Diagnostic using VAG 1551 Scan tool. When using the VAS 5051 tester, observe instructions in the tester's user manual.

Indicated on display

Operating modes 1 and 2 are displayed alternately.

Scheme 301

Note. If nothing appears in display

Operating instructions for Scan Tool (ST)

1. Switch ignition on.
2. Switch off level control system manually (pressing button twice > 5 seconds on manual control head)
3. Press -Print- button to turn on Scan Tool(ST) printer. Indicator lamp in button must light up.

1. Press button 1 to select "Rapid data transfer" operating mode 1.

When indicated on display

Scheme 302

Note. The address word 00 initiates the automatic test sequence, i.e. it results in a DTC check on all OBD capable systems in the vehicle via rapid data transfer.

1. Press "34" for address word "Level control system".

Indicated on display

Scheme 303

1. Press -Q- button to confirm input

Scheme 304

Indicated on display

Scheme 305

1. Indicated on display after approx. 5 seconds
2. Press button.

Indicated on display

Scheme 306

Note. Pressing the -HELP- button will print out an overview of all of the possible functions.

1. Press button -1- twice for the "Login procedure" and press -Q- button to confirm input.

Scheme 307

Indicated on display

1. Press -Q- button to confirm input

Indicated on display

Scheme 308

1. Press button 0, 8, 3, 6 and 7.

Indicated on display

Scheme 309

1. Press -Q- button to confirm input

When indicated on display

Scheme 310

1. Press buttons 0 and 4

When indicated on display

Scheme 311

1. Press -Q- button to confirm input

When indicated on display

Scheme 312

1. Input display group number.
2. Press buttons 0, 2 and 6.
3. Press -Q- button to confirm input

When indicated on display

Scheme 313

1. Press uparrow - button to continue

When indicated on display

Scheme 314

Note. Press downarrow - button to return to GE 26

Indicated on display after expiration of 65 seconds

Scheme 315

Note. However, the filling procedure can only be aborted prematurely by exiting the display group number.

1. Press uparrow - button to continue

When indicated on display

Scheme 316

1. Press up arrow - button to continue

When indicated on display

Scheme 317

Note. Press down arrow - button to return to GE 28

Indicated on display after expiration of 65 seconds

Scheme 318

Note. However, the filling procedure can only be aborted prematurely by exiting the display group number.

1. Press up arrow button to continue.

When indicated on display

Scheme 319

1. Press up arrow button to continue.

When indicated on display

Scheme 320

Note. Press down arrow - button to return to GE 30.

Indicated on display after expiration of 65seconds

Scheme 321

Note. However, the filling procedure can only be aborted prematurely by exiting the display group number.

1. Disconnect diagnostic cable from Data Link Connector (DLC).

Other filling procedures can follow in the above mentioned scheme. the order (filling air springs - front axle, air springs -rear axle, pressure reservoir) can be specified as desired.

Note that upon exiting the filling mode, the regulation still remains manually switched off, as long as it is not switched on or a speed of v > 15 km/h is recognized.

System venting (Allroad)

It is possible to perform a ventilation of the air spring system without having to loosen mechanical connections.

System filling via On Board Diagnostic (OBD) must only be performed with the vehicle standing!

Note. The air spring system (pressure reservoir, air springs, pressurized air lines) can be vented up to the residual pressure of < 3.5 bar via VAG tester. Venting the pressure reservoir is possible without entering a login code (display group number 20 - 21). Venting the air springs is performed separately for front /rear, where the correction login-code must be entered right away (display group 22 - 25). Venting is only possible after manually switching off the regulation. Switching off and on of the regulation is performed with the VAG tester (Fct. > 10, channel 10) or via manually pressing button for up and down (press button twice > 5 seconds). Time frame for venting is limited to 65 seconds. However, it is possible to perform the function several times in sequence to accumulate a longer venting time. It is possible to perform a filling procedure in stages using the up and down arrow buttons of the VAG tester.(buttons 1 / 3 of VAG1551 tester have the additional assignment downarrow - button / uparrow - button)

1. Data is transmitted between the control module and the VAS 5051 tester or VAG 1551 Scan Tool (ST) via operating mode "Rapid Data Transfer".
2. DTC memory is designed for permanent memory and is therefore not dependent on voltage supply.

1. Battery voltage at least 11 V
2. Ground (GND) connections at engine and transmission OK
3. Engine off
4. Automatic transmission in position "P" or "N"

Work sequence

1. Connect VAS 5051 tester with VAS 5051/1 diagnostic wire with the ignition switched off. Alternately, VAG 1551 Scan Tool (ST) can also be attached using VAG 1551/3A adapter.

Note. The following description only explains implementation of On Board Diagnostic using VAG 1551 Scan tool. When using the VAS5051 tester, observe instructions in the tester's user manual.

Indicated on display

Operating modes 1 and 2 are displayed alternately

Scheme 322

Note. If nothing appears in display

See operating instructions for Scan Tool (ST).

1. Switch ignition on.
2. Switch off level control system manually (pressing button twice > 5 seconds on manual control head)
3. Press -Print- button to turn on Scan Tool(ST) printer. Indicator lamp in button must light up.
4. Press button 1 to select "Rapid data transfer" operating mode 1.

When indicated on display

Scheme 323

Note. The address word 00 initiates the automatic test sequence, i.e. it results in a DTC check on all OBD capable systems in the vehicle via rapid data transfer.

1. Press "34" for address word "Level control system".

Indicated on display

Scheme 324

1. Press -Q- button to confirm input

Indicated on display

Scheme 325

Scheme 326

1. Indicated on display after approx. 5 seconds
2. Press --> button.

Indicated on display

Scheme 327

Note. Pressing the -HELP- button will print out an overview of all of the possible functions.

1. Press button -1- twice for the "Login procedure" and press -Q- button to confirm input.

Indicated on display

Scheme 328

1. Press -Q- button to confirm input

Indicated on display

1. Press button 0, 8, 3, 6 and 7.

Indicated on display

Scheme 329

1. Press -Q- button to confirm input

Scheme 330

When indicated on display

1. Press buttons 0 and 4

When indicated on display

Scheme 331

1. Press -Q- button to confirm input

When indicated on display

Scheme 332

1. Enter display group number.
2. Press buttons 0, 2 and 0
3. Press -Q- button to confirm input

When indicated on display

Scheme 333

1. Press up arrow button to continue.

When indicated on display

Scheme 334

Note. Press down arrow button to return to GE 20.

For indication on display after expiration of 65seconds or pressure lower than 3.5 bar in pressure reservoir

Scheme 335

Note. However, the venting procedure can be aborted prematurely by exiting the display group number.

1. Press up arrow button to continue.

When indicated on display

Scheme 336

1. Press up arrow button to continue.

When indicated on display

Scheme 337

Note. Press down arrow button to return to GE 22.

For indication on display after expiration of 65 seconds or pressure lower than 3.5 bar in pressure reservoir

Scheme 338

Note. However, the venting procedure can be aborted prematurely by exiting the display group number.

1. Press uparrow - button to continue

When indicated on display

Scheme 339

1. Press up arrow button to continue.

When indicated on display

Scheme 340

Note. Press down arrow button to return to GE 24.

For indication on display after expiration of 65 seconds or pressure lower than 3.5 bar in pressure reservoir

Scheme 341

Note. However, the venting procedure can be aborted prematurely by exiting the display group number.

If the residual retaining pressure of 3.5 bar is not reached after expiration of 65 seconds, the message "...venting function aborted" appears instead of the message "venting function done".

1. Disconnect diagnostic cable from Data Link Connector(DLC)

Other filling procedures can follow according to the above mentioned scheme. The order (venting air springs - front axle, air springs -rear axle, pressure reservoir) can be specified as desired.

Note that upon exiting the filling mode, the regulation still remains manually switched off, as long as it is not switched on or a speed of v > 15 km/h is recognized.

Component overview

All plastic air connections must be tightened to 2 Nm.

The plastic air connections must be bolted in between marks on air hose. See MARKINGS .

Note. The following list refers to items in (Scheme 345).

1. Electrical connection compressor drive
2. Intake- /exhaust line
3. Air dryer
4. Level Control Pump Temperature Sensor -G290
5. Auxiliary noise insulation
6. Level Control Pressure Sensor -G291- The 4 suspension strut valves -N148-,-N149-, -N150-,N151- and Level Control Accumulator Valve -N311- are incorporated in one valve unit. Tightening torque for bolt in center of valve unit between connections:4 Nm Securing valve block to base plate.3.5 Nm
7. Compressor
8. Electric motor
9. Pneumatic vent valve
10. Solenoid for level control system -N111
11. Pressure line, 2 Nm
12. Pressure line connection at compressor Color mark:Black
13. Connection left front suspension strut Color mark:Red
14. Connection pressure reservoir Color mark:Yellow
15. Connection right rear suspension strut Color mark:Blue
16. Connection left rear suspension strut Color mark:Gray
17. Connection right front suspension strut Color mark:Green

Scheme 342

Note. The following list refers to items in (Scheme 346).

1. Flange nut Tightening torque: 10Nm
2. Shielding piece
3. Securing piece
4. Flange bolt Tightening torque: 23Nm
5. Compressor unit
6. Flange nut Tightening torque: 23Nm
7. Spiral spring
8. Damper element Tightening torque of nut: 6 Nm

Scheme 343

Scheme 344

1. Perform a system ventilation. See «SYSTEM VENTING (ALLROAD)»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__system-venting-allroad) .
2. Remove stabilizer bar. See «STABILIZER BAR & BUSHINGS»(/audi/a6/c5-1997-2001/remont/suspension-front/#suspension-front) .
3. Loosen flange nut for shielding piece.
4. Loosen hose at shielding piece.
5. Remove shielding piece.
6. Loosen hose -1- and connector -2- at compressor.
7. Loosen flange nuts. NOTE: Nuts at damper element must not be loosened!
8. Remove compressor unit.

Scheme 345

1. Secure compressor element with flange nuts. Tightening torque: 23 Nm
2. Secure hose -1 at compressor unit. Tightening torque: 2 Nm
3. Connect connector -2- at compressor unit.
4. Secure shielding piece. Tightening torque: 10 Nm NOTE: Curved plastic exhaust blow-off line at compressor must not contact shielding piece when installing. Lower part of compressor and blow-off valve must not contact shielding piece at insulation material. Corrugated tube hoses with electrical wires and intake or blow-off hose of compressor must not contact insulation material of spare wheel cavity. Electrical wire for blow-off valve must not be pulled tight. Free swinging of the compressor must be ensured. Tighten hose at shielding piece. Install stabilizer bar. See «STABILIZER BAR & BUSHINGS»(/audi/a6/c5-1997-2001/remont/suspension-front/#suspension-front) .

Scheme 346

1. Remove driver's side luggage compartment side trim See «TRIM PANELS (SEDAN)»(/audi/a6/c5-1997-2001/remont/exteriorinterior-trim/#interior-trim) or «TRIM PANELS (AVANT)»(/audi/a6/c5-1997-2001/remont/exteriorinterior-trim/#interior-trim) .
2. Loosen connector at control module
3. Loosen Ground (GND) connection at chassis (arrow)
4. Remove control module in direction of travel.

Vehicles from VIN

4B 1N 057 986 (rest of world)

4B 1N 056 142 (USA)

Scheme 347

1. Slide control module on rib of bracket and clip in.
2. Connect connector at control module
3. Tighten Ground (GND) wire at body. Tightening torque: 11 Nm
4. Install driver's side luggage compartment side trim.

See TRIM PANELS (SEDAN) or TRIM PANELS (AVANT) .

Vehicles up to VIN

4B 1N 057 986 ( rest of world)

4B 1N 056 142 (USA)

For vehicles before the above mentioned VIN it is possible, that no Ground (GND) wire was installed on the old control module. As replacement parts, only current control modules with shielding and Ground (GND) cable are available.

Scheme 348

1. If necessary, drill a hole -b- with 4 mm diameter as depicted in illustration using measurement -a- = 20. (Scheme 351)
2. Re-manufacture corrosion protection.
3. Slide control module on rib of bracket and clip in.
4. Tighten Ground (GND) cable at body using bolt with part number N 906 567.01.
5. Tightening torque: 3.5 Nm
6. Connect connector at control module
7. Install driver's side luggage compartment side trim. See «TRIM PANELS (SEDAN)»(/audi/a6/c5-1997-2001/remont/exteriorinterior-trim/#interior-trim) or «TRIM PANELS (AVANT)»(/audi/a6/c5-1997-2001/remont/exteriorinterior-trim/#interior-trim).

Dynamic Ride Control DRC -RS6

Dynamic Ride Control (DRC) system

(Scheme 352) applies to Sedan and Avant.

Installation locations

Note. The following list refers to items in (Scheme 352).

1. Right front suspension strut See «FRONT SUSPENSION STRUT»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__front-suspension-strut) .
2. Right line
3. Right rear suspension strut See «REAR SUSPENSION STRUT»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__rear-suspension-strut) .
4. Right center valve See «CENTER VALVE»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__center-valve) .
5. Left center valve See «CENTER VALVE»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__center-valve) .
6. Left rear suspension strut See «REAR SUSPENSION STRUT»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__rear-suspension-strut) .
7. Left line
8. Left front suspension strut See «FRONT SUSPENSION STRUT»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__front-suspension-strut) .

Scheme 349

Center valve

Note. The following list refers to items in (Scheme 353).

1. DRC line to rear suspension strut
2. DRC line to rear suspension strut
3. Center valve
4. Hexbolt Tightening torque: 23 Nm
5. Gasket
6. Hex nut Tightening torque: 23 Nm
7. Bracket
8. Bracket
9. Bolt Tightening torque: 9 Nm

Scheme 350

Front suspension strut

Tightening torques

1. Tightening torque: 18 Nm
2. Tightening torque: 16 Nm
3. Tightening torque: 16 Nm
4. Tightening torque: 18 Nm

Scheme 351

Rear suspension strut

Tightening torques

1. Tightening torque: 25 Nm
2. Tightening torque: 18 Nm

Scheme 352

General information

Exclusive use is to be made of approved oil for filling or topping off . See Parts catalog.

Replacement shock absorbers and lines are supplied empty.

Filling is to be performed only at ambient temperature (approx. 20° C).

Shock absorbers are only to be filled in the installed position.

Line and shock absorber must be drained, evacuated and filled separately.

Vehicle must not be allowed to stand on its wheels when DRC system is open (for example, open line/shock absorber connection).

Valves on filling appliance are open when shutoff levers are in parallel with direction of flow.

Draining, evacuation or filling of lines is to be performed in area of rear axle/spare wheel well. Pay attention to the following

1. Remove heat shield in area of exhaust system.
2. Unfasten bolted joint of center unit at spare wheel well.

Filling appliance V.A.S 6209

Note. The following list refers to items in (Scheme 356).

1. Adapter for vehicle with vent valve
2. Connecting hose
3. Venturi nozzle with air discharge hose
4. Valve
5. Pressure reducer
6. Pressure gauge with valves and filler hose
7. Suction hose
8. Used-oil tank Identification: Red dot
9. Fresh-oil tank Identification: Green dot

Scheme 353

Fresh-oil tank, filling

1. Attach suction hose -7- to fresh-oil tank. (Scheme 357)
2. Immerse free end of suction hose -7- in oil in storage container.
3. Close valve -4-. (Scheme 357)
4. Attach valve -4- to fresh-oil tank.
5. Attach venturi nozzle -3- to valve -4-.
6. Connect compressed-air hose to venturi nozzle -3-. (Scheme 357)
7. Slowly open valve -4- and draw oil into fresh-oil tank from storage container.

Max. quantity 1.5 litres

Scheme 354

Note. Oil may foam as it is drawn in. Interrupt suction process to allow foam to settle.

Oil from shock absorber or line, Extracting

Scheme 355

Scheme 356

Scheme 357

1. First fill fresh-oil tank. See «FRESH-OIL TANK, FILLING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__fresh-oil-tank-filling).
2. Screw on adapter -1- at line or shock absorber to be drained. (Scheme 358) NOTE: If line is to be drained, this must be performed at rear axle as shown.
3. Attach pressure gauge with chain -6- at suitable location on vehicle and connect filler hose to fresh-oil tank -9-. (Scheme 359)
4. Connect adapter -1- to pressure gauge -6-.
5. Attach connecting hose -2- to pressure gauge -6- and connect free end to used-oil tank -8-. (Scheme 359)
6. Attach valve -4- to used-oil tank -8- (valve closed).
7. Attach venturi nozzle -3- to valve -4-. (Scheme 359)
8. Set valves as follows: A = Open (lever parallel to direction of flow). (Scheme 360) B = Closed (lever at right angles to direction of flow) C = Open (lever parallel to direction of flow) D = Closed (lever at right angles to direction of flow)
9. Connect compressed-air hose to venturi nozzle -3-. (Scheme 360)
10. Slowly open valve -4- at used-oil tank as far as it will go.

Oil is extracted.

1. Assist extraction process by repeatedly opening valve -D- slightly and closing it again immediately.
2. Extract as much oil as possible (minimum residual quantity).

Used-oil tank, draining

Scheme 358

1. Extract oil from line or shock absorber. See «OIL FROM SHOCK ABSORBER OR LINE, EXTRACTING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__oil-from-shock-absorber-or-line).
2. Place suitable container next to used-oil tank -8- to collect used oil. (Scheme 361)
3. Attach connecting hose -2- to used-oil tank -8- and hold free end over container.
4. Close valve -4- (lever at right angles to direction of flow). (Scheme 361)
5. Attach valve -4- to used-oil tank -8-.
6. Attach pressure reducer -5- to valve -4-. (Scheme 361)
7. Pull out rotary handle at pressure reducer -5- and turn it counter-clockwise as far as it will go.
8. Attach compressed-air connection to pressure reducer -5-. (Scheme 361)
9. Set pressure to 0.1 bar.
10. Slowly open valve -4- and force as much oil as possible out of used-oil tank -8-. (Scheme 362)
11. Close valve -4-. (Scheme 362)
12. Reset pressure reducer -5- to 0 bar.

Note. A small residual quantity of oil is permitted. An empty used-oil tank is absolutely essential for the next stage, "evacuation".

Scheme 359

Shocker absorber or line, evacuating

Note. Used-oil tank must be empty. Shock absorbers must be evacuated and filled separately. Shock absorbers must be disconnected for evacuating and filling lines from control valves to front shock absorbers.

Scheme 360

1. Connecting and preparing filling station. See «OIL FROM SHOCK ABSORBER OR LINE, EXTRACTING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__oil-from-shock-absorber-or-line) .
2. Evacuate connected component (shockabsorber/line). See «OIL FROM SHOCK ABSORBER OR LINE, EXTRACTING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__oil-from-shock-absorber-or-line) .
3. Generate vacuum of at least minus 0.9 bar.
4. Continue with evacuation process at min. minus 0.9 bar for at least 2 minutes.
5. Vent filler line -6- of pressure gauge. To do so, open valve -B- only slightly during evacuation process and draw in oil from fresh-oil tank -9- as far as pressure gauge (no bubbles).
6. Close valve -C-.
7. Close valve -4-.
8. Disconnect compressed-air line.
9. Perform leak test. NOTE: Vacuum must remain stable for at least 2 minutes at minus 0.9 bar.

Scheme 361

Shock absorber/line filling

Note. "Shock absorber or line evacuation" must already have been performed. Vacuum must have been built up as described under "Evacuating shock absorber or line"

Scheme 362

1. Evacuating shock absorber or line. See «SHOCKER ABSORBER OR LINE, EVACUATING»(/audi/a6/c5-1997-2001/remont/electronic-suspension/#self-leveling-suspension__shocker-absorber-or-line-evacuating).
2. Valve -A- open. (Scheme 365)
3. Valves -B- to -D- closed
4. Attach compressed-air connection to pressure reducer -5-. (Scheme 365)
5. Completely close pressure reducer.

Display: 0 bar

1. Attach pressure reducer -5- together with attached compressed-air connection to fresh-oil tank -9-. (Scheme 365)
2. Set pressure reducer to 2 bar.
3. Open valve -B-. Oil flows out of fresh-oil tank -9- into connected component (can be seen from reduction in level in fresh-oil tank). (Scheme 365)
4. Slowly increase pressure at pressure reducer -5- to 5 bar. NOTE: Pressure reading is to be taken at pressure gauge -6-, not at pressure reducer. see scheme 142 This completes component filling procedure.
5. Close valve -A-. see scheme 142
6. Close valve -B-.
7. Close pressure reducer -5- (pull out rotary handle at pressure reducer -5- and turn it counter-clockwise as far as it will go).
8. Detach adapter from vehicle.

Scheme 363

DRC system connection

1. First connect front shock absorbers to line.
2. Connect center valve to rear shock absorbers.
3. Finally connect center valve to line leading to front shock absorbers.

Scheme 364

Scheme 365

1. To check power supply, see «SERVOTRONIC, CHECKING VOLTAGE SUPPLY»(/audi/a6/c5-1997-2001/remont/steering-column-switches/#steering) .
2. To check vehicle speed signal, see «SPEED SIGNAL, CHECKING»(/audi/a6/c5-1997-2001/remont/steering-column-switches/#steering__speed-signal-checking) .
3. To check Servotronic valve, see «SERVOTRONIC VALVE, CHECKING»(/audi/a6/c5-1997-2001/remont/steering-column-switches/#steering__servotronic-valve-checking) .

See also:
• ON BOARD DIAGNOSTIC (OBD)
• EMERGENCY (BACK-UP) BATTERY, SWITCH ON/OFF, RESET TIME REGISTER
• RADIO SYSTEMS
• PARKING BRAKE
• DEACTIVATING/ACTIVATING JACK MODE FOR RIDE HEIGHT SYSTEM (ALLROAD)
• WHEEL REPLACEMENT/WHEEL INSTALLATION, ASSEMBLY NOTES
• STABILIZER BAR & BUSHINGS
• TRIM PANELS (SEDAN)
• SERVOTRONIC, CHECKING VOLTAGE SUPPLY
• SPEED SIGNAL, CHECKING
• SERVOTRONIC VALVE, CHECKING
• MARKINGS
• APPLICATION OF GROUND DISTANCE DIMENSIONS
• INSTALLING
• AIR UNIT MOUNT, ASSEMBLY OVERIEW
• CONNECTOR SYSTEM
• 2-WHEEL AIR SUSPENSION, CHARGING SYSTEM
• AIR LINE FROM SENSOR TO AIR SPRING SHOCK ABSORBER
• INSTALLATION OF AIR STRUT
• LEVEL SENSOR (ALL WHEEL DRIVE), ASSEMBLY OVERVIEW
• SYSTEM VENTING (ALLROAD)
• SYSTEM FILLING (ALLROAD)
• BASIC SETTING (ALLROAD), PERFORMING
• MOUNTING BRACKET (ALLROAD SUSPENSION), REMOVING AND INSTALLING
• PRESSURE RESERVOIR, ASSEMBLY OVERVIEW
• FRONT SUSPENSION STRUT
• REAR SUSPENSION STRUT
• CENTER VALVE
• FRESH-OIL TANK, FILLING
• OIL FROM SHOCK ABSORBER OR LINE, EXTRACTING
• SHOCKER ABSORBER OR LINE, EVACUATING