Koni Suspension Installation VW Bora 85KW TDI

Hi everyone,
Is there anything I should be aware of (tips, optimal timing, etc.)?
Best regards, Hueso.

Torque isn't that important. The main thing is that it's tight .
More importantly, you need a second person to help you. You'll definitely need that extra assistance.
It's simple at the back. Just screw on the shock absorbers, and lift the car up on both sides.
Replace the feathers and send the whole thing back.
But pushing the shock absorbers out of their mounts from the front is a tedious job.
if it's done alone.

Enjoy the suspension system!

@SoupOfTheDay
Thank you for your answer. I know what you mean , I tried it at the beginning and gave up, I couldn't do it. I tried putting karamba in there first, let's see if I can get it loose tomorrow. It's really difficult!

Here's what I did to help myself: Spray some Caramba or WD-40 on it;-) Then, insert a suitable, strong, and long wrench into the gap at the back of the mounting point and wedge it against the driveshaft (this frees up your hands to push the shock absorber out). Hitting the shock absorber from below doesn't really help, as everything moves along with it. The best approach is to place a single wheel nut wrench on the driveshaft and lever it upwards.

I wonder how they do it in the workshop.
There has to be some kind of feather-like expression somewhere in the world.

@SoupOfTheDay
I'm going to the hardware store today to get a pair of pliers and some spring clamps.
Maybe I could borrow it from a specialist, but they usually don't like to lend things out.
Best regards, Hüso.

Hello,

Quote:

Torque isn't that important. The main thing is that it's tight.

It's strange that no one at VDA has noticed this yet. Companies invest huge amounts of money in assembly processes to ensure that torque specifications are met precisely. And that's just in the development phase...

Maybe a suggestion for improvement to the VDA?

Michael II wrote:

It's strange that no one at VDA has noticed this yet. Companies invest huge amounts of money in assembly processes to ensure that torques are precisely adhered to. And that's just in the development phase... Maybe a suggestion for improvement to the VDA?

It's great that you use a torque wrench for every screw.
I only use it for relevant parts, such as cylinder head bolts.

I really don't want to waste my time trying to figure out what's wrong with every messed-up screw somewhere.
And the best part is; so far, they have all held up .

Hello,

Quote:

It's good that you use a torque wrench for every screw.

Hmm, I actually thought this was referring to suspension screws (often stretch bolts), not every screw in general, right?

Quote:

Installation of Koni suspension on a VW Bora 85KW TDI PD (AJM)

And there I am, working with the torque wrench, just as you requested.

Hi,
I was the one with the question . But, once again, on the subject of something, it seems there is also a specialized...
'Key from VW to loosen the front damper?!'

'Quote here'
What do you mean? Are you referring to the drive shaft, or the shock absorber from the wheel bearing housing?

There's a special tool from VW that you need once you've removed that one bolt from the shock absorber to the wheel bearing housing. It's like a socket that allows you to pry the housing apart, and then the housing almost comes out on its own.
Then, remove the screw at the top of the shock absorber, and the shock absorber will come out.

On the right side, you still need to loosen the inner joint of the driveshaft. Otherwise, you won't be able to lower the wheel hub assembly far enough to remove the shock absorber.

Do you understand what I mean? *gg*
'Quote from'

Can you confirm this?

Hello,

That is the tool.

Matra 3424

'Okay, so I've got the suspension components installed. The rear was no problem; I didn't even have to remove the tires. The front was much more difficult. I highly recommend using good spring compressors. Then, try to gently pry the rear of the wheel bearing housing apart with a screwdriver or something similar. You'll also need to secure the lower spring perch (use a broom handle and then carefully lower the car a bit!). Then, I ended up hitting the wheel bearing housing because I simply didn't have the patience or time anymore. So, plan more time for this, so you can loosen the wheel bearing housing more easily.'

And how does it handle with your suspension?

I also have Koni yellow ones inside.

Awesome!

Sure, here is the translation of the text from German to English:

"LG."

This is an abbreviation for "Liebe Grüße," which means "Best regards" or "Best wishes."

@SoupOfTheDay
It drives hard ! I'm very satisfied, but I still have some work to do with the alignment. When I only follow the curves in the front (right, left), it seems like the car is at different heights! Now, I want to go to the TÜV (German technical inspection authority) to register my 18' tires (size 225/40) and the suspension, let's see if that goes well, and then I'll go for the wheel alignment.

But I believe you'll only be able to register the suspension once you've also had the alignment adjusted.

What did you pay for the suspension?

I assume it's threaded.

Sure, here is the translation of the text from German to English:

"LG" is an abbreviation for "Liebe Grüße," which means "Best regards" or "Best wishes" in English.

Yes, it's a threaded mechanism with adjustable stiffness, and I got it for €706, including a warranty and invoice!