Bilstein B8 5100 - User Manual

E4
-
WM5
-
Y656A00
MOUNTING I
N
STRUCTION
Created: 07.30.19 E4-WM5-Y656A00_4 page 1 of 6 latest revision: 07.13.21
IMPORTANT! READ THIS FIRST!
Installation of shock absorbers 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 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 suspension products are gas-filled and are highly pressurized.
• Never place any BILSTEIN product in a vise or use a clamp on any BILSTEIN product.
• Never apply heat near any BILSTEIN product.
• 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 piston rod and seal.
• All mounting fasteners for shocks and struts 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.
CAUTION!!!
Before disassembling the front 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.

Summary

General Safety and Installation Guidelines

Critical Safety Precautions

Essential safety warnings and installation requirements for BILSTEIN products, including handling pressurized components and proper tool usage.

Front Suspension Disassembly Warning

Warning regarding front suspension disassembly, emphasizing coil spring preloading and vehicle manufacturer procedures to prevent injury.

B8 5100 Ride Height Adjustment

Circlip Installation for Ride Height

Guide on placing the circlip in the correct groove to adjust ride height on B8 5100 models, ensuring proper seating.

OE Shock Absorber Disassembly

General Ride Height Disclaimer

Explains how ride heights are influenced and the risks associated with suspension modification, recommending safety measures.

Disassembly Steps

Procedures for removing the existing shock and spring unit, noting clocking, compressing the spring, and removing the OE shock.

Bilstein Shock Absorber Assembly

OEM Dust Boot Trimming

Instructions for trimming the OEM dust boot for B8 5100 series shock absorber assembly when using specific circlip locations.

Bilstein Shock Absorber Installation

Spring Seat and Bump Stop Installation

Steps for installing the spring seat adapter, spring seat, isolator, and bump stop cap onto the new Bilstein shock absorber.

Spring and Top Hat Assembly

Procedure for compressing the spring, assembling it with the shock, and installing the top hat assembly, ensuring correct seating and alignment.

Fastener Tightening and Final Installation

Instructions for tightening fasteners, including specific torque values and warnings against impact wrenches, and final vehicle installation and alignment checks.

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

The Bilstein E4-WM5-Y656A00 is a mounting instruction manual for a shock absorber system, specifically the B6 4600 and B8 5100 Series. This document provides comprehensive guidance for the installation and maintenance of these suspension products, emphasizing safety, proper procedures, and the necessary tools and expertise required for a successful installation.

Function Description

The Bilstein E4-WM5-Y656A00 mounting instruction manual serves as a critical guide for the installation of Bilstein B6 4600 and B8 5100 Series shock absorbers. These shock absorbers are designed to enhance vehicle suspension performance, providing improved ride quality, handling, and stability. The manual outlines the steps required to correctly install these gas-filled, highly pressurized suspension components, ensuring they function as intended within the vehicle's suspension system. It details how to prepare the vehicle, disassemble existing components, modify parts as needed, and reassemble the new Bilstein shock absorber module. The instructions cover critical aspects such as adjusting ride height for the B8 5100 series, proper clocking of mounts, and the correct tightening of fasteners. The overall function of the manual is to facilitate a safe and effective installation process, preventing damage to the vehicle or injury to the installer, and ensuring the optimal performance of the Bilstein suspension products.

Usage Features

The manual highlights several key usage features for the Bilstein shock absorbers and the installation process:

• Professional Installation Requirement: The document strongly emphasizes that installation requires special tools and expert knowledge, and must be performed by a professional automotive suspension technician. This underscores the complexity and precision involved in handling these components.
• Application-Specific Use: Bilstein products must only be used for their specific, intended application as indicated in the application guide. Using them for other purposes can lead to serious injury or death.
• Set Installation: When replacing other brands, Bilstein shock absorbers should always be installed as a set to ensure balanced performance.
• Chassis Hoist Requirement: A chassis hoist is mandatory for installation, and the vehicle must be securely attached to prevent slipping, falling, or moving.
• Ride Height Adjustment (B8 5100 Only): For the B8 5100 series, the manual provides detailed instructions on how to adjust the ride height by placing a circlip in one of six appropriate grooves. This allows for customization of the vehicle's stance and suspension travel. A table of typical lift heights for different engine variants and drive types is provided to aid in this adjustment.
• Component Orientation: Specific instructions are given for the correct orientation and clocking of components, such as the lower T bar mount relative to the upper mount studs, and the spring seat adapter. This ensures proper fitment and function.
• Spring Compression: The use of an appropriate spring compressor is crucial for compressing the coil spring, releasing load before disassembly, and assembling the new shock absorber module.
• Dust Boot Modification: For certain circlip locations (3-6) on the B8 5100 series, the OEM dust boot needs to be trimmed by 1.5 inches. This modification ensures proper clearance and function with the new shock absorber.
• Fastener Management: The manual specifies the use of new flange lock nuts supplied by Bilstein and provides torque specifications for tightening. It explicitly warns against reusing original lock nuts and using impact tools for tightening fasteners to prevent damage to screw threads.
• Post-Installation Checks: After installation, several critical checks are required, including suspension caster and camber, brake compensator and anti-lock brake system, and headlight aim. These adjustments ensure the vehicle operates safely and correctly with the new suspension.

Maintenance Features

The manual also touches upon aspects related to the maintenance and handling of the Bilstein shock absorbers, primarily focusing on preventing damage and ensuring longevity:

• No Impact Tools: A strict warning is issued against using impact tools for loosening or tightening fasteners, as this can destroy screw threads. This emphasizes the need for careful, manual tightening to specified torque values.
• Single-Use Fasteners: Self-locking fasteners must only be used once. This ensures the integrity and security of critical connections.
• Component Reuse Guidelines: Original equipment components should only be reused if they are in good condition; otherwise, they must be replaced with new ones. This prevents the compromise of the new suspension system by worn-out parts.
• Piston Rod and Seal Care: Installers are advised never to remove the slight film of oil on the piston rod and seal, as this film is crucial for the proper functioning and longevity of the shock absorber.
• No Disassembly or Repair: Bilstein suspension products are gas-filled and highly pressurized. The manual explicitly states never to attempt to open or repair any Bilstein product, as this can lead to serious bodily injury or death and voids any warranty.
• No Heat Application: Heat should never be applied near any Bilstein product, as it can compromise the integrity of the pressurized components.
• No Clamping or Vising: Bilstein products should never be placed in a vise or clamped, as this can damage the pressurized components.
• Warranty Voidance: Any attempt to misuse, misapply, modify, or tamper with any Bilstein suspension product voids any warranty, reinforcing the importance of following instructions precisely.
• Pre-Assembly Fastener Tightening: All mounting fasteners for shocks and struts must be securely tightened before tension is placed on the suspension system, unless otherwise specified. This ensures components are properly seated and secure before being subjected to vehicle weight.
• Regular Alignment Checks: Post-installation, the vehicle's wheel alignment must be checked and adjusted to the manufacturer's specifications. This is crucial for tire wear, handling, and overall vehicle safety, and implies that periodic checks may be necessary over the vehicle's lifespan.

Bilstein B8 5100 Specifications

General

Type	Shock Absorber
Adjustability	Non-Adjustable
Finish	Zinc Plated
Warranty	Limited Lifetime
Series	B8 5100
Material	Steel
Position	Front or Rear
Compatibility	Vehicle-specific