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Canadian T3 air suspension retrofit

75K views 141 replies 41 participants last post by  Mariusz  
#1 ·
Figured I should start a thread about my current project. I'm going to retrofit the air suspension in my 2015 ExecLine R-Line. I will document as much of the retrofit as I can here. I'll try to includes as many pics as possible, as well as part numbers and wiring diagrams. I currently have everything except the air strut assemblies (on order), the body acceleration sensors (on order) and the load sill lower switch/trunk trim.

The latest Cayenne (958 ) comes with the air suspension in North America, so that makes it easy to get everything required except for the two dash switches. I thought about purchasing a wrecked Cayenne, but the cheapest I could find was around $9000 CAD. I acquired everything for under $3000 CAD.

I'm no stranger to turning a wrench. I'm a heavy duty mechanic, have owned over 30 Volkswagens and Audis, and have done some pretty neat swaps (16v G60 swap in my '81 Rabbit S, 1.8T K04 syncro swap in my '92 Passat wagon, VR6 swap in an '84 GTI, several MK2 1.8T swaps, etc). Overall it's not a terribly involved retrofit per se. You need:

compressor assembly and air lines
air tank
air trut assemblies
computer module
dash switches (2 of them)
FR and RR height sensors
body acceleration sensors (2 of them)
random mounting hardware (brackets, bolts, nuts, grommets, etc)
Load sill switch and right trunk trim panel (allows you to lower just the rear axle for ease of loading/unloading things)
lots of wires


Pictured below is the air compressor assembly complete with air lines and grommets, air tank, levelling module, and some pigtail harnesses.
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I'll post more pics later when all the parts have arrived. I hope to start the install within the next three weeks.

I'm also retrofitting a Webasto parking heater as well, just waiting on a few last pieces to arrive. I'll create a separate thread for that, of course. Also planning on retrofitting a complete 4Xmotion system too (transfer case, rear diff).
 
#2 ·
Watching with eager anticipation... I plan on doing this to my NAR 2012 sport when time, money, and wife approval allows.
 
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#3 ·
These are going to be interesting threads.


Would you be kind enough to list part numbers where you know them?
And lots of pix too please!!
 
#4 ·
Got some work done today. Mounted the compressor assembly, air tank, and ran the air lines. Pretty neat that the body has all the correct openings already, just plugged with grommets.

Few pics for now. When it's all done and running, I'll post a complete thread with lots of pics, part numbers, coding, wiring diagrams, etc.

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#7 ·
Sorry for the lack of updates. I'm waiting on a few final pieces to come from Europe and Volkswagen. In the mean time, I've got it pretty much all set. Compressor assembly, air tank, air lines, dash switches, and 90% of the wiring is complete. I'll install the airbags when it's all ready, obviously. Running the front left airline was a huge pain, as it runs along the bottom of the rain tray area; which meant I had to remove pretty much everything in there. :(

I've taken lots of pics, so when it's all done and moving up and down, I'll create a proper thread complete with lots of pics, part numbers, and wiring diagrams.

I also need one of our ROW friends to send me their levelling control module coding. Posted on MyTreg but haven't received any replies as of yet. :(

Here's a couple of pics to tide you over for now. :)

Air compressor assembly mounted:
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Air tank mounted:
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#9 ·
I suggest we get a group buy going for NA friends to swap this over to our Tregs. If we could get 50-100 owners to go in we could probalby get some good deals on parts or even have an aftermarket become interested in this. Im willing to throw 4k out for air ride on my Treg.
 
#13 ·
Very optimistic estimation. If only you could source wrecked Cayenne. I checked OEM cheapest options. Just few main components: Controller, Compressor assembly, Valves block, Tank and 4 Struts. The budget is around 9,390 US Dollars. Plus the remaining bits: sensors, wiring, hoses, bolts and nuts, etc. There are some substitutes available. However, no aftermarket alternatives for some positions, like main controller. Don't even try to search brand new Cayenne parts. The price is 1.5-2 times higher.
 
#10 ·
You can get everything needed (with exception of the two dash switches) from a 958 Cayenne (2011-2016).

I'm also in the process of acquiring the needed bits for a 4Xmotion swap (transfer case and locking rear diff).
 
#15 ·
I've been able to piece together all the bits off eBay and the dealer. I got some parts off eBay in North America (air bag struts assemblies, module, air tank) and some parts of eBay in Europe (complete air compressor assembly with uncut airlines and grommets for $250 CAD, level sensors, acceleration sensors, pigtails, dash switches). I bought random bolts and hardware from the local dealer. All in, I'm into this for about $2900CAD, which isn't too bad at all, I believe.

The Webasto parking heater retrofit (thread coming soon) was about $550 CAD, and the 4Xmotion system will be around $2000CAD (due to heavy shipping weight from Europe).
 
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#16 ·
#22 ·
I think the fitting of the auxiliary Webasto diesel powered heater was standard on the Generation 1 (T1 anfmd T2) European Touareg Tdis but the parking heater function was a factory option and was not standard.
 
#27 ·
It has been stopped for 2 weeks. :( I'm waiting on a crucial part (front right level sensor) that's coming from Europe. Been a month already. If I don't have it by next Wednesday, I'll order one locally.

I "test ran" the system 2 weeks ago. Plugged the module and fuses in, made some changes in vcds and voila, DIS displayed some errors and vehicle level status. Was able to run the compressor and test the valve block.

I need the euro coding for the brake module (03 ), unfortunately vcds doesn't have a label file for it so I have no idea which bit to byte to change. I'm contemplating buying a VAS5054 but unsure if that would help me in this case.
 
#31 ·
Finally received the right front level sensor. Made up a bunch of wiring harnesses and connected things up and did a trial run. Has codes obviously since the air struts aren't installed yet, and I haven't re-wired the left front and rear level sensors. You can see the vehicle height display on the left side of the DIS.

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I'm really hoping to have this all done and running before Christmas. Lesson learned - don't start any projects until you have all the parts. :roll:
 
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#32 ·
This is super cool....i want to do all this and 4x motion to mine too...so jealous
 
#33 ·
4xMotion retrofit will happen in the spring. I've already acquired the dash switch, modules, and some pigtails. Need to source the transfer case, rear diff and axles.
 
#35 ·
Parts list for the air suspension, or 4xMotion?
 
#38 ·
If the parts for this retrofit aren't too crazy expensive (ie using air struts from a Cayenne) I would love to do this one day.


sigh... one day


Please please please keep detailed records of what you're doing. One day will be here eventually!
 
#40 ·
Well, she's all operational now! :) Gotta calibrate the level once more and tidy up the harnesses and install the load sill lowering switch, but the Touareg goes up and down now. :grin2:

 
#43 ·
Truly IMPRESSIVE!!!!!!
Thanks! :)

It's been running great the past few days. Air suspension is so much more comfortable and smoother than the steel suspension. Even on Sport mode, I feel bumps less.

I need some help from the ROW people who have a 2011+ Touareg with air suspension: could you please post/PM me your 03-brake module long coding? VCDS doesn't have a label file for the T3/T4 brake module, and I need to code it for air suspension.
 
#48 ·
Enjoying the post, and I just joined the forum. I just bought (2 days ago) a 2014 Tdi to use as a tow vehicle for our travel trailer. I'm hoping to do as you did, and swap (just) the rear suspension with air to help support the weight on the hitch. Do you know if the 2003-06 Cayenne rear air springs have the same mounting points as the 2011-16. From pictures, it looks like the damper control valve was relocated but otherwise the mounting looks the same. The 03-06 are quite a bit cheaper. For a first test, I'm planning to use a simple electronic pressure control valve to maintain constant pressure. If that works well I might add a PLC and level sensors to make it more automatic. Also wondering if the shock is basically in "comfort" mode when no power is applied. Cheers.
 
#50 ·
You need 2011+ parts, they're completely different from the previous 03-10 parts. The damper is on max firm when no current is applied, max soft when 1.8A is applied.

It might have been easier to convert an Australian Touareg to left-hand drive!
I quite doubt it, it would end up costing me over 65,000 CAD to have it landed here at least. Then converting it to LHD would've been a hell of a larger task than retrofitting the air suspension. Plus it needs to be at least 15 years old.
 
#52 ·
If the all new Touareg and air sus for NF/FL model are the forbidden fruits for NA, why not to consider Audi Q7? They share same platform, the prices for new Treg are almost at par with Q7 now, I see no advantages in terms of off-road capabilities, and Audi positioned itself as progressive prestigious luxury?
 
#54 ·
Audi stopped bringing over the Diesel Q7's with the 4L body, 4M is petrol only. :frown2:
Question for you, do you guys get rear lockers in your 4L Audi Q7's?