[bishbosh]

Guys, I need your help please.

This afternoon I've installed the rear shocks and springs. After fighting with the exhaust and snapping the xenon level sensor arm I managed to get the stuff installed.

However I'm now wondering if I did it wrong.

Basically I missed out part #4 from the following picture (which shows OEM parts). This was because at the time I couldn't get the bumpstop out from it.



I did not reuse part number 3 as the shocks come with their own bump stops. The Bilsteins do have a large washer under the blue dust cap which cushions the bumpstop in the same way that part #4 does with the original bumpstop.

Here you can see both side by side.



This is the original cap on the original shock. The large washer on the Bilsteins sits in the same way on top of the lip on the new shocks.



Do I need to use these caps? This is what it currently looks like installed. The brownish foam bit is part #6 in the realoem pic.



Cheers
Dave

[Aragorn30d]

what you've done seems to be correct IMO.

The bilsteins come with their own bumpstops, covers etc and the parts 3 and 4 on the original unit are not required, as they're already provided on the new shock.

I presume part 6 has a solid sleeve in the middle of it to clamp up against the damper rod?

[bishbosh]

Yes part 6 has a solid sleeve in it and when I clamped it up it was nice and tight. The top of the blue dust cover has a metal ring at the top that you can just see in the 2nd picture. This pushes into the brown foam bit by about a mm or so until it contacts the solid sleeve.

Edit: As I've already installed the shock I might take it off again and double check if I have time. I'm currently halfway there with the fronts. I expect it'll be quicker the 2nd time around as I know what needs doing in which order

Cheers

[bishbosh]

Right, after studying the instructions more carefully you do have to install part #4, otherwise the blue sleeve is pushed off its perch by the foam, you can see this starting to happen in the last picture.

Good news is it only took me an hour to do the drivers side and that includes removing trim panels The more awkward passenger side will be done tomorrow after my replacement levelling sensor gets delivered

I also finished the fronts, approx 2 hours per side.

Took the car for a spin and the conclusion is that the alignment is badly out. Pulls to the left a litter and have to turn right slightly to drive straight. Will try and book it in for a Hunter alignment on Wednesday

[Icekube]

Originally Posted by Aragorn30d

what you've done seems to be correct IMO.

The bilsteins come with their own bumpstops, covers etc and the parts 3 and 4 on the original unit are not required, as they're already provided on the new shock.

I presume part 6 has a solid sleeve in the middle of it to clamp up against the damper rod?

you forgot that we did cut out the bump stop from that metal cup (part 4) and used it on the new shocks when we installed mine

[wallsmk2]

You most definitely do need this part. As you say, it keeps everything in line. The fitter who installed mine omitted this and it caused the strut to sit at an angle which squished the top mount rubbers until they wore unevenly. Eventually this caused a knock as the top of the strut hit the mount. You could wiggle the damper through the chassis.

[bishbosh]

Wow, yes I expect the part cushions the rubbers, thinking about it it does make sense.

Replacement height level sensor has arrived so that will be fitted at the same time as the metal cap and then I'll try and get a build thread going!

Car is booked in for an alignment tomorrow

Cheers all for your help!

[Aragorn30d]

Yeh looking at the diagram i guess that does make sense, the top of the cup will act to evenly preload the foam and support it.

[wallsmk2]

fitting instructions for rear struts http://cdn.media.oscaro.com/pdf/16/e4-wm5-y301a00.pdf

[bishbosh]

Originally Posted by wallsmk2

fitting instructions for rear struts http://cdn.media.oscaro.com/pdf/16/e4-wm5-y301a00.pdf

Was looking for that yesterday! Found my paper copy though when I got home

[bishbosh]

Car is now back together alignment tomorrow!

[bishbosh]

Got the car aligned today, here's the result

Turns out it was badly out at the rear which I had expected, surprised that the fronts were ok though. Earlier the handling was shocking! Like the car kept wanting to go left and then right, I also kept getting the DTC light flashing on mild bends. I reckon the toe being out so much was causing all that. Got the camber sorted too so now all is good and no more DTC light

[Aragorn30d]

They could have sorted the front end while they were there, instead of leaving it with uneven toe and camber. Lazy barstewards!

[bishbosh]

Yeah, I had hoped they would. In fairness they did try to sort the toe but after loosening the pinch bolt the track rod end wasn't having any of it.

Apparently (and I've heard this from several folk) there is more negative camber on the front left as it's set up for UK roads. Not that you can move the top mount much anyway! The front camber settings are pretty much what I saw last time the alignment was done - at a different outfit.