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5 . 3 BU M P STO P R EMOVAL AND FIT T ING O F UPP ER BRAC KET
1.
Remove the two bump stops (Figure 1 and 2).
2.
Drill out the blind rivet (Figure 3) of the LED head light sensor. Use a drill of 5 mm (Not all models will have
this sensor).
3.
The chassis bracket assembly has two parts (See Figures 4, 5 and 6). Put the two parts together and offer
them up to the frame left vacant of the bump stop. Now slide the upper of the two chassis brackets inside
the lower of the two until the assembly is loosely attached to the bump stop frame with the holes in
alignment.
4.
Offer the upper bracket up to the chassis bracket assembly and attach it using a single M8 x 20mm bolt
and a single serrated washer (Figures 7 and 8).
5 .4 ATTAC HME N T O F T HE LED-LIG HTS SENS O R
1.
The sensor can be attached on almost the same position but now to the lib of the upper bracket (Figures 9
and 10) with the M5 x 14, washer and flange nut (Pos. 11, 12 and 13 page 6).
2.
The sensor arm remains unchanged.
3.
Our upper bracket is designed in the way that the sensor will be in the same position as it was. Still you
have to check the height of the headlights.
4.
Correction can be done by shifting the clamp around the shock absorber a bit up or down, till the height
of the headlights is correct again.
5.
Tighten the sensor arm bracket and check the height of the headlights again.5.5 Attachment of the Lower
bracket and the Bellows
5 . 5 ATTAC H ME N T O F T HE LOWER B R AC KET AND THE BELLOW S
1.
Unscrew the two bolts from the bracket that attaches the torsion beam assembly to the axle (Figure11).
2.
Reattach the bracket that secures the torsion beam to the axle, thereby also securing the lower bracket to
the axle (Figure 12).
Take care the lower bracket rests flat.
3.
See Section 5.7 - "Tube Connection and Disconnection, Cutting and Routing" : Use black tubing for the
left-hand bellow and blue for the right-hand bellow.
4.
Feed for the right side the blue (left side is the black hose) tube from the topside trough the biggest hole of
the upper bracket.
5.
Manually compress the bellow and connect the tube to the air bellowthen bung the end of the tube to
maintain the compressed state (Figure 13).
6.
Shift the air bellow carefully between the brackets and guide the tube (Figure 13).
7.
Release the bung from the tube. This allows air into the bellow, which consequently expands upwards
towards the upper bracket
(Figure 14).
8.
Attach the bellow to both brackets using two M8 x 16mm bolts and two serrated washers on both sides of
the bellow (Figure 14 and 15). Do not fully tighten at this stage because the bellow may require alignment
once inflated (see Section 5.9 and Figure 16).
9.
The distance between the top face of upper plate of the bellow and the bottom face of the lower plate
should now be brought to approximately 14cm. Manoeuvre the bellow such that it is in good vertical
alignment between the upper and lower brackets and tighten the screws.
9 | INSTALLATION MANUAL | AUXILIARY AIR SUSPENSION | VOLKSWAGEN CRAFTER DRW AND 4X4 / MAN TGE DRW AND 4X4
FEB 2021