5.3 PREPARATION
2. Secure the front wheels, use wheel chocks on both sides of both front wheels.
3. Take the ground terminal from the battery when work to electricity
is involved.
4. Lift the rear of the vehicle till there is working space of approximately 15 cm between bump stop and rear
axle.
5.4 ATTACHMENT OF LOWER BRACKET TO BELLOW
1. Attach the lower bracket to the bellow as indicated by the diagram of Section 4. Do not fully tighten at
this stage because...
•
otherwise it may prove difficult or impossible to slot the U-bolts between the lower plate of the bellow and
the lower bracket (in step 3 of section 5.6).
•
the bellow may require alignment once inflated (see Section 5.10, Figure 21)
5.5 BUMP STOP REMOVAL AND FITTING OF UPPER BRACKET
1. Unscrew and remove the bump stop — Figures 1 and 2. The hole vacated by removal of the bump stop will
be used for attachment of the upper bracket.
2. Attach the upper bracket to the chassis using the M10 x 1.25 x 30mm bolt and M10 spring washer —
Figures 3 and 4.
5.6 FITTING OF LOWER BRACKET AND BELLOW
1. See Section 5.8 - “Tube Connection and Disconnection, Cutting and Routing” : Connect a tube to the
bellow. Use black tubing for the left-hand bellow and blue for the right-hand bellow.
2. Remove the U-bolts that attach a clamping plate to the leaf spring and then remove and discard the
plate itself — Figures 5 and 6
3. Place the U-bolts over the lower bracket and through their original mounting holes. Secure the bolts
using the original washers and nuts—Figures 7 and 8. Tighten all four nuts to torque 110Nm (81lbf.ft).
4. See figures 7, 8 and 9 : Place the air bellow on the lower bracket paying attention to orientation—see
arrows on Figures 7 and 8. Also observe the routing of the air line from the side of the bracket.
5. Attach the bellow to the lower bracket by using the two M8 x 16 bolts and two M8 spring washers. Note
that access to these bolts is now a little restricted but is still possible (Figures 9, 10 and 11). Do not fully
tighten at this stage because the bellow may require alignment once inflated (see Section 5.10, Figure 21)
6. Attach the bellow to the upper bracket by using two M8 x 16 bolts and two M8 spring washers—Figures 12
and 13. Do not fully tighten at this stage because the bellow may require alignment once inflated (see
Section 5.10, Figure 21)
9 | INSTALLATION MANUAL |
AUXILIARY AIR SUSPENSION | X244:
CITROËN JUMPER/RELAY, FIAT DUCATO, PEUGEOT BOXER (2002-2006)
JULY 2021
