Volkswagen Phaeton: Self-Leveling Suspension, Servicing

Self-leveling suspension, servicing .
1 27
Volkswagen Phaeton
43 - 2
Self-leveling suspension, servicing

Troubleshooting of air spring struts and level control
system
Condition Verification Possible causes Corrective action

Replace air spring
strut
front 40-3, Air
spring strut
Leakage at air spring removing and
shock absorber installing
rear 42-4, Air
spring strut,
removing and
installing
Very slow loss of Observe level over longer
pressure time period and identify Air line, servicing
vehicle sits leakage using commercially Leakage at air lines 43-2, Air line,
crooked after a available leak-detection spray servicing
longer time period 1)
Replace air spring

strut
front 40-3, Air
spring strut
Leakage at residual
removing and
pressure retaining
installing
valve
rear 42-4, Air
spring strut,
removing and
installing
Vehicle sits Perform "Guided Fault Replace Level
crooked Finding" using Vehicle Vehicle level sensors Control System
no leakage Diagnosis, Testing and faulty Sensor
Information System VAS 43-2, Self-
5051 levelling
Linkage or retainer suspension system,
for Level Control components and
System Sensor is bent installation
locations
Vehicle sits too Vehicle has bottomed
high, cannot be 1.) Check if = vehicle has out
lowered sufficient ground clearance
Pinched air lines,
servicing, 43-2,
2.) Check air lines and line Air line plugged, Air line, servicing
routing pinched or frozen Frozen and plugged
air lines, blowing out
with compressed air
Self-leveling suspension, servicing . 2 27
3.) Perform "guided fault

Exhaust valve or air
finding" using vehicle
spring valve
diagnosis, testing and
malfunctioning
information system VAS
5051
Replace air spring
strut
front 40-3, Air
4.) Perform steps 1-3, and if spring strut
no problems are found up to Residual pressure removing and
this point, the residual retaining valve stuck installing
pressure retaining valve is rear 42-4, Air
stuck spring strut,
removing and
installing
Inspection of
electrical system
finding" using vehicle
relays, harness
connectors, wiring
and fuses
5051
Pressure accumulator Replace accumulator

6.) Identify leakages at leaking
accumulator with
Vehicle sits commercially available leak Air line or connectors Air line, servicing
crooked and can detection spray to accumulator 43-2, Air line,
not be raised or leaking servicing
can only be raised
very slowly Replace air supply
unit
finding" using vehicle Exhaust valve faulty,
43-2, Air supply
diagnosis, testing and leaking or open
unit, removing and
installing
5051
Replace air supply
8.) Perform steps 5-7, and if unit
no problems are found up to Air supply unit faulty 43-2, Air supply
this point, the air supply unit unit, removing and
is faulty installing
Replace air spring
strut
front 40-3, Air
spring strut
Vehicle level is uneven, and removing and
Air spring faulty
when attempting to change installing
"Quick" pressure
vehicle level, air escaping rear 42-4, Air
loss
from the faulty air spring is spring strut,
audible removing and
installing
Air line, servicing

43-2, Air line,
Air line is torn off servicing

Replace air spring
strut,
front 40-3, Air
spring strut
Dampening
removing and
Adjustment Valve
installing
faulty
rear 42-4, Air
spring strut,
Test drive, and adjust the removing and
dampening level. The change installing
Insufficient must be clearly noticeable. Replace air spring
damping Pay attention to "rumbling strut,
noises" when driving over front 40-3, Air
uneven roadways. spring strut
removing and
installing
Strut worn rear 42-4, Air
spring strut,
removing and
installing
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 10 - 30 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.
- 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 problem-
free 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

replaced.
Self-levelling suspension system, components and

installation locations
Air supply unit with solenoid

valve block
Can be tested in "guided fault

finding" using Vehicle
information system VAS 5051
Removing and installing

43-2, Air supply unit,
removing and installing
Location: under spare tire well
With motor for compressor-

level control system V66
With level control pump

temperature sensor G290
Level control system control

module J197

Location: Behind left rear E-

Box

43-2, Level control system
control module J197 ,
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 installing
Left rear air spring strut
With left rear dampening

adjustment valve N338

Left rear wheel acceleration

sensor G339


Left and right rear wheel

acceleration sensors G339 /
G340 , removing and
installing
Discontinued as of chassis
number: 3D4 to 00001
Left Front Body Acceleration

Sensor G341


Left and right Front Body
Acceleration Sensor G341 /
G342 , removing and
installing
Left front wheel acceleration

sensor G337


Left and right front wheel
G338 , removing and
installing
Left front air spring shock strut

With left front dampening

Left Front Level Control System

Sensor G78



Left and right front level
G289 , removing and
installing
Right front wheel acceleration

sensor G338


Left and right front wheel
G338 , removing and
installing
Right Front Level Control Sensor

G289


Left and right front level
G289 , removing and
installing
Right front air spring shock strut
With right front dampening


Right Front Body Acceleration

Sensor G342



Left and right Front Body
Acceleration Sensor G341 /
G342 , removing and
installing
Right rear wheel acceleration

sensor G340


Left and right rear wheel
G340 , removing and
installing
Right rear level control system

sensor G77


Left and right rear level
G77 , removing and installing
Rear right air spring shock

absorber
With right rear dampening


Rear Body Acceleration Sensor

G343


Rear Body Acceleration
Sensor G343 , removing and
installing
Level control system control module J197 , removing and

installing
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 installing fuse holder, relay carrier, E-boxes
and control modules
.
- Unclip connectors - B, C - at control module.
- Bend retaining tabs - 1 - 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 5051 . Vehicle Diagnosis,
Testing and Information System VAS 5051
Left and right front level control system sensors G78 / G289 ,
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
Removing
- Raise vehicle.
- Disconnect electrical connection.
- Remove hex socket head bolts - 2 - and hex nut - 3 -

while counter holding at studs - 1 - .
Installing
Installation is in reverse sequence of removal.

and Information System VAS 5051 . Vehicle Diagnosis,
Testing and Information System VAS 5051
Left and right front wheel acceleration sensors G337 / G338 ,

Assembly Overview: Left and right front wheel acceleration

sensors G337 / G338
Air spring strut

Hex head bolt, 10 Nm

Left and right front wheel acceleration sensors G337 /
G338 with retainer
Removing
- Raise vehicle.
- Remove bolts - 2 - and remove Left and right front wheel

acceleration sensors G337 / G338 with retainer.
Installing
Left and right Front Body Acceleration Sensor G341 / G342 ,

Assembly Overview: Left and right Front Body Acceleration

Sensor G341 / G342
Front Body Acceleration Sensor G341 / G342

Hex nut, 9 Nm
Removing
- Raise vehicle.
- Remove hex nut - 2 - and remove Front Body

Acceleration Sensor .
Installing
Left and right rear level control system sensors G76 / G77 ,
Assembly Overview: Left and right rear level control system

sensors G76 / G77
Hex bolt, 10 Nm
Hex nut, 10 Nm
Rear Level Control System Sensors G76 / G77
Removing
- Raise vehicle.
- Remove hex bolts - 1 - and hex nuts - 2 - , remove Front

Body Acceleration Sensor .
Installing

and Information System VAS 5051 Vehicle Diagnosis,
Testing and Information System VAS 5051 .
Left and right rear wheel acceleration sensors G339 / G340 ,

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
Removing
- Raise vehicle.
- Remove hex bolts - 3 - and remove Left and right rear

wheel acceleration sensors G339 / G340 .
Installing
Rear Body Acceleration Sensor G343 , removing and installing
Assembly Overview: Rear Body Acceleration Sensor G343
Hex nut, 9 Nm
Rear Body Acceleration Sensor G343
Removing
- Remove right luggage compartment trim
Repair Manual, Body Interior, Repair Group 70, Luggage

compartment and cargo area trim; Luggage compartment
trim, removing and installing on sides
- Remove hex nut - 1 - and remove Rear Body Acceleration

Sensor G343 .
Installing
Air line, servicing
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 .
- 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
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
Volkswagen, Skoda, Seat, Audi
Air supply unit
With motor for compressor-

level control system V66
With level control pump

temperature sensor G290
Installed in spare wheel well

from vehicle underside

43-2, Air supply unit,
Muffler
Spring clamp
Intake hose
Rubber bushing
Air supply unit fasteners

included in kit
Rubber bushing

included in kit
Coil spring

included in kit
One coil spring is packaged

separately and must be
installed across from the
solenoid valve
Metal sleeve

included in kit
Bolt
9 Nm

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

43-2, Solenoid valve,
Air line
5 Nm
Between solenoid valve block

and air supply unit
Air supply unit, removing and installing
Removing
- Raise vehicle.
- Remove plastic cover below spare wheel well.
- Disconnect connectors - 2 - and - 3 - .
- Remove air lines - arrows - .
- Protect air lines from dirt.

- Remove hex bolts - 4 - and remove air supply unit - 1 -

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 - 4 - and tighten.
- Install air lines to solenoid valve - A - and tighten.
Tightening torque
Plastic cover to spare wheel well 2 Nm
Air lines to solenoid valve block 5 Nm
Air supply unit to spare wheel well 9 Nm
Line arrangement on solenoid valve

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 rear air spring strut
- 5 - Black, (approx. 150 mm long) to compressor
- 6 - Yellow, accumulator
- Connect electrical connectors - 2 - and - 3 - .
- Check basic setting of self-levelling suspension 43-2,

Self-levelling suspension, basic setting .
Solenoid valve, removing and installing

Removing
- Raise vehicle.
- Remove plastic cover below spare wheel well.
- Disconnect air lines - arrows - .
- Protect air lines from dirt.
- Disconnect connectors - 2 - and - 3 - .
- Remove air line - arrow - from compressor.
- Disconnect connector - 1 - .
- Remove hex bolts - 2 - 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 43-2, Line

arrangement on solenoid valve .
Tightening torques
Plastic cover to spare wheel well 2 Nm
Air lines to solenoid valve block 5 Nm
Solenoid valve to air supply unit 10 Nm
Self-levelling suspension, basic setting
- Check basic setting of self-levelling suspension Vehicle

Diagnosis, Testing and Information System VAS 5051 .
- 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

5051 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 5051 .
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.

Volkswagen Phaeton: Self-Leveling Suspension, Servicing

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Volkswagen Phaeton: Self-Leveling Suspension, Servicing

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Self-leveling suspension, servicing .

Self-leveling suspension, servicing

Condition Verification Possible causes Corrective action

Replace air spring

3.) Perform "guided fault

Pressure accumulator Replace accumulator

Air line, servicing

Air line is torn off servicing

Perform the following test under these conditions:

The vehicle must be cold and can not be moved

Room temperature must be between 10 - 30 C and

The vehicle must be sitting on a level surface

- Move vehicle with Front Information Display Control Head

- Switch engine off.

- Remove connector from Level Control System Control

- Measure vehicle height at all four wheels.

- After 24 hours, measure again vehicle height and

If the vehicle is sitting crooked, a leak is present at

- Check affected air spring strut and corresponding air line

Air line connections

Residual pressure retaining valve

Check front air spring strut when installed, and check

If an air spring strut is faulty, it may be possible that oil from

- Remove affected line from air spring strut and solenoid

- Blow line clean with compressed air several times. To do

- 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

If oil is found in internal line, air supply unit must be

Self-levelling suspension system, components and

Air supply unit with solenoid

Can be tested in "guided fault

Removing and installing

Location: under spare tire well

With motor for compressor-

With level control pump

Level control system control

Can be tested in "guided fault

Location: Behind left rear E-

Removing and installing

Location: Left rear

Left rear level control system

Can be tested in "guided fault

Assembly overview 43-2,

Left rear air spring strut

With left rear dampening

Can be tested in "guided fault

Left rear wheel acceleration

Can be tested in "guided fault

Assembly overview 43-2,

Left and right rear wheel

Left Front Body Acceleration

Can be tested in "guided fault

Assembly overview 43-2,

Left front wheel acceleration

Can be tested in "guided fault

Assembly overview 43-2,

Left front air spring shock strut

Can be tested in "guided fault

With left front dampening

Left Front Level Control System

Can be tested in "guided fault

diagnosis, testing and