First air suspension issue
 

4 weeks into D3 ownership and the air suspension throws a wobbly.

After a night of very heavy rain, went out this morning in the D3.

Started normally and set off along the farm track, after 50 yards the green low clearance light pops up and goes out again. Green light stays out until I am on the main road driving at 60mph and it comes on again, except now it stays on.

After another mile the amber light pops up, indicating issue with suspension. Car feels fine, so I carry on to my destination which was only another mile or so.

Arrive with both lights still on, so I check the MMI, and all looks fine.

I get out, expecting to see either a wonky car or a car on the decks but no its at its normal ride height and looks perfectly ok.

So I go and do the shopping, get back to car which still looks ok, hop in and start the engine. Green low clearance light still on, but the amber one has now gone out.

On the MMI I tried the different settings, Lift - the car goes up and the green light goes out, Auto - the car goes back down and the green light pops back on, dynamic the car goes down and the green light stays on. So I pop it back to auto, car goes up and now the green light goes out.

Drove home, no issue at all. Tried the MMI settings again, the car still goes up and down normally and all seems like it did last night when I parked it.

When my laptop has some charge in it, I'll pop out and scan it with VCDS. Who knows what I'll find, watch this space.

Fault codes

Saturday,04,January,2014,10:11:14:10074
VCDS Version: Release 10.6.4
Data version: 20110418



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Address 34: Level Control Labels: 4E0-910-553.lbl
Control Module Part Number: 4E0 910 553 E HW: 4E0 907 553 E
Component and/or Version: LUFTFDR.-CDC H05 4290
Software Coding: 0015510
Work Shop Code: WSC 02313 785 00200
VCID: 2545F5A79571
2 Faults Found:

01772 - Signal from Level Control Pressure Sensor (G291)
008 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 3
Fault Frequency: 3
Reset counter: 64
Mileage: 207890 km
Time Indication: 0
Date: 2014.01.02
Time: 08:36:08

01400 - Suspension Level Control
002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 2
Fault Frequency: 1
Reset counter: 64
Mileage: 207901 km
Time Indication: 0
Date: 2014.01.04
Time: 08:58:15

Given that the light goes out when it goes up a bit, I'd be inclined to check the level sensor first if everything looks level.

I was just looking up the codes online, and spotted that the first one 01772 occurred on Thursday, which would have been when the car was first started having been left for a few days. This maybe a red herring since previous to this the car had only done a few days of short journeys, so the battery will not have been tip top.

The low level exceeded is only showing as occurred once, so maybe things are not as bad as I thought.

How can I check the level sensor?

The sensor has thrown the error 3 times, and the control error would tie in with you driving off for a bit and then the yellow coming on.

I'll try and get a look later to spot where that sensor is, but if it's the one I think it is, then should be one on each corner with a lever resting on the lower control arm.

Those three faults could be because of three first thing starts perhaps then. I do wonder, where I have to park here on the farm the car is not on the level, so one of the four corners ends up with more gap between tyre and wheel arch because of uneven ground. At work and elsewhere, the ground is always even and flat.

I have cleared the codes and for now they have not returned. I'll scan the level module again in a few days and see what crops up. Previous to this I last cleared the faults on the 30/12/13. The car was then driven on the 31st Dec, 2nd, 3rd and 4th Jan. Yesterday it completed four journeys and the rest were two.

I do however have a feeling the 01772 will return, I have just looked through the first scan I managed to do just after buying the car. At the time there were a lot of the errors (and I mean lots) due to the car having a duff battery. Buried in the level control module is this.

01772 - Signal from Level Control Pressure Sensor (G291)
008 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 3
Fault Frequency: 162
Reset counter: 37
Mileage: 202012 km
Time Indication: 0
Date: 2013.05.06
Time: 11:59:35

So it looks like that fault has been occuring on and off for several thousand miles. Maybe the compressor has issues first thing.

Must be the season for problems.

Just been out to the car, suspension still at normal height after sitting for more than 24 hours.

Start engine, no suspension lights. After 5 mins running, amber light pops up again. All options still available under car on MMI.

Stop engine, and restart. All lights are out, car still goes up and down. Left running for 10 mins, no faults showing or anything.

Select LIFT, get out of car and listen to compressor by nearside front (difficult at the moment because the exhaust flexi has a hole in it). Not sure, but what should a good compressor sound like? Should it be audible above the sound of the engine, what does a failing one sound like.

From Auto to Lift, how long should it take before the rear and front of the car raise?

When left on Automatic how often would you expect to hear the compressor kick in?.

Sitting in the car, with the heater and aircon off I can hear the relay clicking as the compressor switches on/off.

Can I use VCDS to measure anything to tell me weather its the compressor or something else.

The car is having its cambelt and what have you changed on Tuesday, I'll ask the specialist to take a look at the compressor whilst they have the front end off. The specialist is 15 miles from here and they are collecting it and dropping it back later.

If the compressor is declared dead/dying then I'll most likely have to layup the D3 and go back to the D2 for the time being until I can get it fixed. I have found a source for a replacement compressor/relay in Germany, but I need the car to be reliable daily, and to be sure that replacing the compressor and relay is the first thing to try.

This may be worth while looking into see attachmens

Car is back from the workshop after the cambelt change. The suspension issue is FIXED, hopefully.

After changing the cambelt, they set about my suspension. First they checked all the components externally, so the Valve block and its air and supply connections, the compressor connections. Then onto VCDS.

First they checked the suspension level control measuring blocks and discovered that the car thought that each corner was at completely different heights.

Before sorting that, they then checked the electrical connections on each of the level sensors. All were OK, except the NSF which when disconnected showed signs of water ingress. The inside was green from corrosion, so after cleaning it all up everything looked ok so it was reconnected.

Next they sorted out the suspension ride height issue above by recalibrating the whole lot one corner at a time. The car now has all 4 corners at the correct setting, which is good. The car raises and lowers correctly, and all 4 corners look the same.

After a road test the suspension issue itself has now cleared. Hooray (lets hope it stays that way).

BUT the compressor is weak. Rather than replace the whole compressor, they recommend using the repair kit from Ebay and having the existing compressor rebuilt. They have done quiet a few Touregs with the kit, and never had an issue with it. Currently the compressor is running too often ,as it struggles to cope with the demand placed on it. There is no air leak, which is good.

The cost of the work done so far on the suspension, £0. all done for nothing, since they know me.

Now to source the repair kit from Ebay.

Thats a result on the suspension.

The level sensors work by sending a pwm signal back to the module so if there was moisture in there that would definitely screw things up.

Hope you compressor rebuild is as painless.

compressor could also be running too much as it'll be constantly letting air out and pushing it back into the system to try and level it out when it's confused.

Compressor repair kit ordered, want to get this sorted before the compressor gives up completely.

Car is booked in with my friendly local independent VAG specialist for next Tuesday to have the compressor repair kit installed. I know I could do it myself, but the weather and time of year is not the best. The driveway outside the house is currently a sea of mud.

Good luck for the repair... Let me know how you get on. Just lift that is sometimes available or not at the mo, so perhaps the compressor is weak. For £25 I may just buy the kit and suggest the guys fit it when it goes in for the parking sensor replacement next week. Mine is 03 so an early one, lowing miles but 10 years old may need the piston rings doing.

Spoke to the mechanic earlier, he has fitted the kit and the suspension is back to full working order. The car now raises and lowers correctly, I'll test it myself when they deliver the car back.

He is bringing the old parts back to show me how bad it was, apparently air was escaping around the compressor piston because of damage to the old part and that is why the pressure was low. I'll post a picture of the old part when I get it back later.

Great! I think this could be my issue too. Did a big drive today and on starting the green light was on and went out after 10 secs or so but no lift. Then after 20 mins of driving, all functions there.

I'll get the eBay kit and suggest they fit as a precaution next week. If you don't mind me asking, how much/how long was the labour for this job?

Many thanks for all your helpful feedback.

Here are the pictures of the old compressor part. You can see the damage, it should be smooth all the way round and mine had some nicks from the outside and quiet bad scoring. Air was escaping round the edge of the part as a result of the damage.

I was charged 3 hours labour, Rick had to spend sometime cleaning up the piston cylinder as it was in quiet a state inside. Suspension is now working great which is a relief until something else breaks.

This is what I purchased, this is the original one. As you can see Andy has sold loads of them, each is handcrafted and tested before being posted.
http://www.ebay.co.uk/itm/161120430069

Ah just ordered this myself!!

Mine getting fitted tomorrow. Fingers crossed!

Mines been fine for 300 miles, until today. I have air escaping from the compressor area, as the compressor starts and stops I can here PSSHHHHT a bit like when you remove a tyre pump from a valve.

I think it only does this as the compressor starts and stops although not sure, at first I thought it may have been a HGV behind me but it did it again on the way home from work.

Could be air escaping from the output air line, or something else. Everything is still working, no fault codes. I'll give the mechanic a call tomorrow I guess.

Probably just an airlock somewhere? The compressor might auto bleed?

The mechanic is popping by my workplace on his way to work tomorrow to have a listen and take the car if he thinks something is wrong. I hope the sound can be replicated on demand.

To confirm, I can replicate it on demand, it appears to be as the compressor shuts off. If I sit in the car and select Lift, so the car uses the air in the tank, then select Dynamic so the car dumps all the air from the struts. Finally select Lift again, so the compressor must run to get pressure back. After the car has raised and the pressure tank is full, the compressor cuts out but just as it stops there is a psssht sound lasting just a fraction of a second. Does it every time, so I can show him tomorrow morning.

The sound maybe normal, but I can't say I have noticed it before.

He has been, and has taken the car back to the workshop. He is happy that something is not right, so will once again gain access to the compressor. Compressor is working fine, but air is escaping from the compressor area when its running.

Maybe it is purging/regenerating the air-dryer?
"The appropriate valves 9a, 9b and 9c, 9d and the electrical exhaust solenoid valve 5 are opened. The air can flow through the exhaust solenoid 5 to open the pneumatic, pilot operated exhaust solenoid 6.
The air leaves the system via exhaust solenoid 6, additional silencer 7 and air filter 8. When air flows through the air drier 2, the desiccant is regenerated."

The sound is quiet loud though, I am sure it must do this in normal operation, pehaps damped by something. I could here it pssshhht as he drove out the car park.

He did the repair last Tuesday, and it was silent on till Sunday night having driven the car for around 5 hours in total during the weekend.

Well all seems ok after my repair so far. All functions there, no compressor banging. The front looks high however, and I'm convinced the ride in comfort is firmer than it was before... Anyway, I'm not complaining I just hope that all is now well.

It's a stress all this air ride stuff... Completely just expect it all to go wrong!

Sounds like you need a recalibration Jonk. VCDS you can do it.

Guys, how much did the whole repair cost you, parts + labour??
Just out off interest, it could be a good preventive maintenance which I could consider doing as long there isn't too much risk and fragile parts or procedures.
Cheers +++

Parts, £25 delivered. I paid 2 hours labour charge for the fix to be installed. Certainly worth doing, in my case it appeared like nothing was wrong except the intermittent fault code. Fault code now gone, and all good apart from the air escaping sound which they are looking at as we speak. I hope its a dodgy connection from the last repair on the compressor and easily fixed.

You can DIY the repair, its quiet easy once you have the compressor off the car.
http://bagpipingandy.com/installation.html

Could you share the fault codes you were getting if you remember, well, have them saved.
Also just for the sake of it Take a little spray bottle with plenty fairly and spray all the connections on all 4 shock absorbers as well at the same time.

Did you take the bumper off to take comp out or wheel and wheel arch off, bumper isn't it??

This the fault code that popped up shortly after I cleared them all.

01772 - Signal from Level Control Pressure Sensor (G291)
008 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 3
Fault Frequency: 3
Reset counter: 64
Mileage: 207890 km
Time Indication: 0
Date: 2014.01.02
Time: 08:36:08

But looking back at the log I did a week after buying the car, it had been present for some months before I purchased it.

01772 - Signal from Level Control Pressure Sensor (G291)
008 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 3
Fault Frequency: 162
Reset counter: 37
Mileage: 202012 km
Time Indication: 0
Date: 2013.05.06
Time: 11:59:35

The compressor has to be removed, and the mechanic I used to change the part removed the front bumper fully, just for ease of access. Since he has the car again today, if I remember I'll ask him when he drops it off. The compressor comes out from the wheel arch side, but one bolt is accessed from the front.

Cheers Manny +++
btw, did you got my PM with reply to your questions, will be calling Chris now

And you say it takes 2hours while compressor is off the car??

Yep, got your PM. At work, so not got the time to digest fully.

2 hours was all in, including removal, refitting and testing.

Cool, no worries, I'm having time off work since 20th Dec till mid Feb so I tried to give you all the info possible to your questions.

Just finished talking to Chris, they will have to check if they or AMD guys, got somewhere on the paperwork sizes because funny thing 3.7 v8 has a slightly bend flex thats why all is custom made by AMD on clamps cos Audi wants I think 1k for both runs as one piece.
You've got all the details and all contact info there and Chris will expect a call from you tomorrow afternoon and you take it from there.

And it is £300 inc. VAT for both exhaust flexes supply and fit, 1.5h max I think

Thanks for all the legwork you are doing for me.

Got my car back this evening, he took the compressor off again and checked it over and says its fine. No signs of leakage from any of the pipes, so I'll see how the suspension goes.

No problemo Manny, just give him a call tomorrow afternoon, ideally after 2 or 4pm.


Where would you get specs of how long should it take to raise and lower suspension to see if there is already a wear/leaks which would slow down the operation??
I assume there should be a leak detecting procedure do0ne by the dealer (like used by commercial gas engineers on gas installation or at least this type)

Or it will throw errors straight away as soon there is loss of pressure ???

The problem I had, which I thought was normal until I saw the car working as it should. Going from Dynamic to Lift, it used to take ages for the front to raise. its now way faster than it was before. I should have timed it before and after repair and I could have posted something.

I am not sure how, but I think using VCDS measuring blocks you can see the compressor output pressure. Repaired it should be 16bar, around 220PSI, before mine was running just 6 bar according to the mechanic, the other 10 were escaping round damaged piston ring.

VCDS it is, will check it in a minute.

How long does it take now from dynamic to comfort etc, could you measure that at some point please??