Air Supply Unit
Pneumatic Level Control System
Air Supply Unit
Special tools, testers and auxiliary items required
• Torque wrench (5-50 Nm) (VAG 1331)
• Torque wrench (5-60 Nm) (VAG 1783)
• Open end spanner insert AF 10 (VAG 1783/1)
Removing
• The air supply unit is installed on the left side, behind the front bumper.
- Place the vehicle on a hoist. Refer to => [ Positioning Vehicle on the Hoist and on its Wheels ] Positioning Vehicle on the Hoist and on its Wheels.
- Vent the system. Refer to => [ System Venting or Filling ] Level Control System.
- Remove the wheel covers, remove the cover cap on light alloy wheels (removal hook in vehicle tool kit).
- Remove the left front wheel.
- Secure the brake disc with a wheel bolt.
- Loosen the quick release fasteners - 1 and 2 - and remove the noise insulation.
- Remove the bolts - 1 - from the front wheel housing liner.
- Remove both bolts - arrows - from the front wheel housing liner.
Do not remove the rear wheel housing liner - 2 -.
- Remove the upper bolt - arrow - from the front wheel housing liner.
• Press the locking pins on the wheel housing liners only about 5 mm into the expanding clip and not all the way through.
• This releases the locking pin so it can be removed.
• When installing, slide the locking pin back and the expanding clip can be used again.
- Press the locking pins on the expanding clips - 1 - on the front wheel housing liner about 5 mm deep into the expanding clip using a screwdriver.
- Remove the expanding clip.
- Repeat the procedure to remove the expanding clip - arrow - in the upper area of the front wheel housing liner.
- Repeat the procedure to remove the expanding clip - arrow - in the rear area of the front wheel housing liner - 1 -.
- Remove the nut - 1 -.
- Disconnect the electrical connectors - 2 -.
- Open the clamp - 1 - and remove the intake hose - 2 - from the connecting piece - 3 -.
- Remove the air line from the air supply unit - arrow -.
- Remove the nuts - 4 - and the air supply unit.
• The illustration does not show the bumper.
Installing
Installation is performed in the reverse order of removal. Observe the following when doing so:
- Install the air supply unit nuts - 4 -. Refer to - item 15 - in => [ Air Supply Unit Assembly Overview ] Pneumatic Level Control System.
- Install the air line - arrow - to the air supply unit. Refer to - item 9 - in => [ Air Supply Unit Assembly Overview ] Pneumatic Level Control System.
- Close the clamp - 1 - and connect the intake hose - 2 - to the connecting piece - 3 -.
- Install the nut - 1 -. Refer to - item 15 - in => [ Air Supply Unit Assembly Overview ] Pneumatic Level Control System.
- Connect the electrical connectors - 2 -.
- Install the front noise insulation.
- Install the wheel housing liner.
- Install the wheel and tighten.
- Fill the system. Refer to => [ System Venting or Filling ] Level Control System.
- Place the vehicle on its wheels. Refer to => [ Positioning Vehicle on the Hoist and on its Wheels ] Positioning Vehicle on the Hoist and on its Wheels.
Air Supply Unit
Special tools, testers and auxiliary items required
• Torque wrench (5-50 Nm) (VAG 1331)
• TORX(R) bit set (VAG 1766)
• Torque wrench (5-60 Nm) (VAG 1783)
• Open end spanner insert AF 10 (VAG 1783/1)
• Spring type clip pliers (VAS 5024A)
Removing
• The air supply unit is installed on the left side, behind the front bumper.
• When installing the air supply unit, install any cable ties that were loosened or cut during removal.
• Clean the air connection area before separating.
- Place the vehicle on a hoist. Refer to => [ Positioning Vehicle on the Hoist and on its Wheels ] Positioning Vehicle on the Hoist and on its Wheels.
- Vent the system. Refer to => [ System Venting or Filling ] Level Control System.
- Remove the wheel covers, remove the cover cap on light alloy wheels (removal hook in vehicle tool kit).
- Remove the left front wheel.
- Secure the brake disc with a wheel bolt.
- Loosen the quick release fasteners - 1 and 2 - and remove the noise insulation.
- Remove the bolts - 1 - from the front wheel housing liner.
- Remove both bolts - arrows - from the front wheel housing liner.
Do not remove the rear wheel housing liner - 2 -.
- Remove the upper bolt - arrow - from the front wheel housing liner.
• Press the locking pins on the wheel housing liners only about 5 mm into the expanding clip and not all the way through.
• This releases the locking pin so it can be removed.
• When installing, slide the locking pin back and the expanding clip can be used again.
- Press the locking pins on the expanding clips - 1 - on the front wheel housing liner about 5 mm deep into the expanding clip using a screwdriver.
- Remove the expanding clip.
- Repeat the procedure to remove the expanding clip - arrow - in the upper area of the front wheel housing liner.
- Repeat the procedure to remove the expanding clip - arrow - in the rear area of the front wheel housing liner - 1 -.
Follow the safety precautions when disconnecting the battery.
- Disconnect the battery ground cable with the ignition switched off.
- Remove the front bumper cover.
- Bring the lock carrier into the service position. Radiator Support
- Remove the left front headlamp.
- Remove the wiring harness bracket - 1 - from the air supply unit bracket.
- Disconnect the electrical connectors - 2 -.
- Carefully cut the air intake hose cable ties - arrow -.
- Loosen the spring clamp - 2 - from the air intake hose - 3 - using the (VAS 5024A).
- Remove the air intake hose - 3 - from the air hose muffler - 1 -.
- Clean the air connection area before separating.
- Remove the connecting piece - arrow - on the air supply unit. Air escapes then.
• The air supply unit is removed with its bracket.
- To remove the air supply unit with the bracket, remove the bolts - 1 through 3 -.
1 Bolt with washer
2 Bolt without washer
Use a T45 TORX(R) bit from (VAG 1766/1) and a open end wrench to remove and install
3 Bolt without washer
for the connector retaining plate and reservoir bracket
- Remove the bolt - 2 - on the fender using the T45 TORX(R) bit - 1 -.
- Remove bolts - 2 and 4 -.
- Remove both air guide hoses - arrows - on the bottom of the lower left air filter housing section. Press the release buttons together to do that.
- Remove both air guide hoses on the bottom of the secondary air injection (AIR) pump motor (V101) and secondary air injection (AIR) pump motor 2 (V189). Press the release buttons together to do that.
- Remove both air guide hoses.
• Mark the AIR pump motor and AIR pump motor 2 connectors before removing them.
• The connector housings are identical and interchangeable.
- Mark the connector - 1 - and release and remove it from the AIR pump motor 2 - 2 -.
- Mark the connector - 3 - and release and remove it from the AIR pump motor - 4 -.
- Remove the nut - 2 - and Air Conditioning (A/C) line - 21 - from the threaded pin.
- Remove the clamp - 1 - from the reservoir if applicable.
- Remove the bolts - 2 - from the reservoir.
- Pull the line - 1 - away from the reservoir to the right and secure it to the subframe - 3 - using a cable tie - 2 -.
- Remove the cable ties securing the wiring harness to the air supply unit bracket, if applicable.
- Remove the bracket - arrows - on the lock carrier.
- Remove the front bolt - 2 - using the T45 TORX(R) bit - 1 -.
- Pull the air supply unit with the bracket back slightly in the wheel housing.
- Disengage both lines - 1 - for the AIR pump motor and AIR pump motor 2 from the air supply unit bracket - 2 -.
- Remove the air supply unit with the bracket.
- Carefully cut through the cable ties - 1 - through - 3 - if the air supply unit will be separated from the bracket.
- Remove the bolts - 1 - and the air supply unit.
- Remove the rubber bushing - 2 - from the air supply unit.
Installing
Installation is performed in the reverse order of removal. Observe the following when doing so:
- Insert a new rubber bushing - 2 - in the air supply unit.
- Tighten the air supply unit bolts - 1 -. Refer to - item 4 - in => [ Air Supply Unit Assembly Overview ] Pneumatic Level Control System.
- Replace the cable ties - 1 through 3 - if the air supply unit was separated from the bracket.
- Install the bracket - arrows - on the lock carrier.
• Do not interchange the AIR pump motor and AIR pump motor 2.
• The connector housings are identical and interchangeable.
- Connect the connector - 1 - on the AIR pump motor 2 - 2 - and the connector - 3 - on the AIR pump motor - 4 -.
- Install the air supply unit - 1 - and reservoir bracket - 3 - as shown in the illustration.
- Tighten the bolts - 2 and 4 - by hand.
- Tighten the air supply unit bolts - 1 through 3 -. Refer to - item 15 - in => [ Air Supply Unit Assembly Overview ] Pneumatic Level Control System.
1 Bolt with washer
2 Bolt without washer
Use a T45 TORX(R) bit and a open end wrench to remove and install
3 Bolt without washer
for the connector retaining plate and reservoir bracket
- Replace the air intake hose cable ties - arrow -.
- Install the A/C line and reservoir.
- Install the left front wheel housing liner.
- Install the left front headlamp.
- Install the lock carrier.
- Install the front bumper cover.
Follow the safety precautions when connecting the battery.
- Connect the battery ground cable with the ignition switched off.
- Install the wheel and tighten.
- Fill the system. Refer to => [ System Venting or Filling ] Level Control System.
- Place the vehicle on its wheels. Refer to => [ Positioning Vehicle on the Hoist and on its Wheels ] Positioning Vehicle on the Hoist and on its Wheels.
- Calibrate the adaptive cruise control. Refer to => [ Adaptive Cruise Control Adjustment with VAS 6190 ] Adaptive Cruise Control Adjustment With VAS 6190.