BILSTEIN E4-WM5-Y716A00 Shock Absorbers Instruction Manual

BILSTEIN E4-WM5-Y716A00 Shock Absorbers

Product Information

The product being referred to in the user manual is the BILSTEIN shock absorbers or other suspension components, specifically the B8 5100 model. These products are designed for automotive suspension systems and are gas- filled and highly pressurized. It is important to note that the installation of these products requires special tools and expert knowledge, and therefore should be performed by a professional automotive suspension technician. The use of BILSTEIN products other than for their intended application may result in  serious bodily injury or death.

Product Usage Instructions

1. Always ensure that the installation of BILSTEIN products is carried out by a professional automotive suspension technician.
2. When replacing other brands, BILSTEIN shock absorbers or other suspension components should always be installed as a set.
3. Refer to the application guide to ensure that the BILSTEIN product is used for its specific, intended application.
4. Use a chassis hoist for the installation process and make sure that the raised vehicle is securely attached to prevent any accidents.
5. Do not place any BILSTEIN shock absorbers in a vise or use a clamp on them. Avoid applying heat near the shock absorbers.
6. Never attempt to open or repair any BILSTEIN product. This can lead to serious bodily injury or death.
7. If disassembling a coil over type suspension, refer to the vehicle manufacturer’s service manual for proper procedures. Compress the coil spring with a spring compressor before disassembling the upper mount.
8. The professional automotive suspension technician should identify any non-OEM components and/or modifications on the vehicle that may interact with the suspension system and evaluate them for potential interference or effect on the function of the BILSTEIN product.

For the B8 5100 model, it is important to place the circlip in the appropriate groove to adjust the ride height. Use appropriate tools to move the circlip and ensure it is fully seated in the groove. Improper installation may cause permanent damage to the shock absorber.
Note: The specific lift heights for the B8 5100 model are provided in the user manual, ranging from 0.3 inches to 1.8 inches.

IMPORTANT! READ THIS FIRST!
Installation of shock absorbers or other suspension components requires special tools and expert knowledge. Accordingly, installation of all BILSTEIN products must be performed by a professional automotive suspension technician. When replacing other brands, BILSTEIN shock absorbers or other suspension components should always be installed as a set. All BILSTEIN products must only be used for the specific, intended application as indicated in the application guide. Any use of any BILSTEIN product other than for its intended use may result in serious bodily injury or death. Always use a chassis hoist for the installation of BILSTEIN products and make certain that the raised vehicle is securely attached to the hoist and/or supported to prevent the vehicle from slipping, falling, or moving during the installation process. If you install any BILSTEIN product without the necessary special tools, expertise, and chassis hoist, you may subject yourself to the risk of serious bodily injury or death. BILSTEIN shock absorbers are gas-filled and are highly pressurized.

• Never place any BILSTEIN shock absorbers in a vise or use a clamp on any BILSTEIN shock absorber.
• Never apply heat near any BILSTEIN shock absorber.
• Never attempt to open or repair any BILSTEIN product, in order to prevent serious bodily injury or death.

Any attempt to misuse, misapply, modify, or tamper with any BILSTEIN suspension product voids any warranty and may result in serious bodily injury or death.

While installing any BILSTEIN product:

• Do not use impact tools for loosening or tightening fasteners, because this may destroy the screw threads.
• Self-locking fasteners must only be used once!
• Reuse original equipment components only if they are in good condition, otherwise replace them with new components.
• Never remove the slight film of oil on the shock absorber piston rod and seal.
• All mounting fasteners for shock absorbers and other suspension components must be securely tightened before tension is placed on the suspension system, unless otherwise specified in the manufacturer’s service manual or in this instruction.

After installing any BILSTEIN product:

• The suspension caster and camber must be checked and/or adjusted to comply with the vehicle manufacturer’s specifications.
• The (load dependent) brake compensator and the anti-lock brake system must be checked and/or reset to comply with the vehicle manufacturer’s specifications.
• The headlight aim must be checked and adjusted. Or, if applicable, adaptive headlights must be checked and recalibrated to comply with the vehicle manufacturer’s specifications.
• If applicable, any/all Advanced Driver Assistance Systems (ADAS) must be checked and recalibrated to comply with the vehicle manufacturer’s specifications.

CAUTION for COILOVER TYPE SUSPENSIONS!!!
If disassembling a coil over type suspension, refer to the vehicle manufacturer’s service manual for proper procedures. The coil spring is preloaded and must be compressed with a spring compressor to release load before the upper mount is disassembled. Failure to follow the vehicle manufacturer’s procedures may cause serious injury or death, and may damage the vehicle.

IMPORTANT
This BILSTEIN product may or may not be compatible with non-BILSTEIN aftermarket products and/or vehicle modifications. It is the responsibility of the professional automotive suspension technician performing the installation to identify any non-OEM components and/or modifications on the vehicle that may interact with the suspension system. These must be evaluated for any potential physical static or dynamic interference with and/or effect on the function of this BILSTEIN product.
IMPORTANT:
PLACE CIRCLIP IN APPROPRIATE GROOVE TO ADJUST RIDE HEIGHT (B8 5100 ONLY).
Use appropriate tools to move the circlip. Ensure that the circlip is fully seated in the groove after moving it (you should be able to rotate it manually in the groove). Install the spring seat in the direction shown only. The circlip must fit completely in the groove inside the spring seat (DETAIL A). Improper installation will cause permanent damage to the shock!

B8 5100 is depicted

• Ride heights indicated are typical. Actual ride height is influenced by which factory suspension the vehicle is equipped with and its condition; optional equipment and accessories on your vehicle, and other vehicle modifications such as replacement coil springs, wheel and tire combinations, etc. Modifying/lifting the suspension to your vehicle may raise its center of gravity and may make it more susceptible to loss of control and/or rollover, which may result in death or serious injury. We strongly recommend that you offset the loss of rollover resistance as much as possible by increasing tire track width, and that you equip the vehicle with a functional roll bar and cage system. Wear seat belts and shoulder harnesses at all times, and avoid situations where a side rollover may occur.

Instructions for disassembly of OE shock absorber module:

• Remove the existing shock and spring unit from the vehicle following all procedures in the vehicle manufacturer’s service manual.
• Note the clocking of the lower T bar mount relative to the studs on the upper mount as shown in Figure 1 (important for reassembly).

• Using an appropriate spring compressor, compress the spring until it can be rotated freely by hand. Then, disassemble the shock and spring unit.
• Remove the OEM shock.

Instructions for assembly of Bilstein B6 4600 or B8 5100 Series shock

absorber module

B6 4600: Skip step E.
B8 5100: Skip step E if using circlip locations #1-#2. If using circlip locations #3-#6, continue to step E. Trimming the OEM dust boot is only necessary if circlip locations #3-#6 are being used.

• Using scissors, cut the OEM dust boot on the dotted line shown below in Figure 2:

The result should look as depicted below in Figure 3:

• Install the supplied spring seat followed by the supplied spring seat isolator onto the new Bilstein shock body as shown. Orient the spring seat and spring seat isolator in the direction shown only. Ensure that the groove inside the spring seat fits over the circlip on the shock body [see page 2 (DETAIL A)]. Improper installation will cause permanent damage to the shock.
• Install the supplied bump stop cap onto the shock body as shown in Figure 5.
• Using an appropriate spring compressor, compress the OEM spring and assemble it with the new Bilstein shock. Ensure that the OEM coil spring is installed in the direction shown only. Refer to Figure 1.
• Install the OEM top hat assembly (which includes the OEM dust boot, OEM top mount plate, and OEM jounce bumper) over the threaded stem on the new Bilstein shock and on top of the spring. Refer to Figure 5.
• Rotate the coil spring until the end of the top coil is seated into the OEM dust boot as shown .

•  Rotate the shock so the lower bushing is aligned with the upper mount studs as noted in step B and shown in Figure 1.

•  Install the provided new flange lock nut and tighten to 45 Nm (34 lb/ft). Use an 8mm wrench to keep the piston rod from rotating while torqueing the lock nut.
  DO NOT USE AN IMPACT WRENCH TO TIGHTEN THE LOCK NUT!

• Release the spring compressor while ensuring that the end of the top coil remains seated in the OEM top hat assembly.

• Install the assembly on to the vehicle and tighten all fasteners to the vehicle manufacturer’s specifications. This completes the installation.

• Check wheel alignment. If necessary, adjust to the vehicle manufacturer’s specifications.

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