Alko air suspension

On the MOT yesterday it passed with flying colours, apart from an advisory on the Alko “Advisory: monitor and repair if necessary.  Additional air suspension bags rubbed on bolt but not leaking”.

I’m sure I remember reading somewhere about this being a known issue.  I saw the air bags and there is a clear mark, but it’s certainly not in any danger of rubbing through at the moment.

What is the general advice for this?  My garage has said he can do it (he is not a camper van specialist, just an all round good car man).  Is it something I need to do immediately, or can it wait?  Or do some people ignore it?  If I do it, is it something a general mechanic can do, or should I go to a specialist?

I appreciate that it’s difficult to give specific advice, but general pointers would be helpful.  I’m generally okay on the day to day stuff, but I’ve zero knowledge of Alko.

Thanks in advance
Sally

Previous thread and advice.....

[You must be registered and logged in to see this link.]

Paul has helpfully provided the link. Having read through it and seen the photographs, you can decide whether the cause of your advisory is that the bolts were incorrectly fitted upside-down (in which case all that's needed is their reinstatement the correct way up) or whether the cause is something else.

If the former is the case, then I suggest you print off a few suitable entries and photos from the thread to show the mechanic (or show them on a device). He may then feel sufficiently confident to replace the bolts one by one (ideally with identical new ones).

Cymro

The main issue is to keep them at the correct pressure, around 1.8 bar on the gauges. If the suspension unit are only marked, then all should be ok, assuming that the pressures are ok. I had the same problem, both had to be changed ( £££££). I actually replaced the bolts with dome headed version( the bolt heads that have the Allen key head) , which certainly gave a larger amount for bolt clearance.

Having started with the post mentioned by Paul, I then found many more posts about this issue. I’m going to have another look at balloon things and see how badly they are marked and work out exactly what’s rubbing on them (the bolts etc). Plus I’m going to top up and see what that’s like over a few weeks.

If all else fails then know I can get them replaced.  Just a bit of a faff really. 

Thanks everyone
Sally

Sally, it is 100% important that when setting the pressure, that the vehicle be on level ground. The volume of the air bags / balloons is quite small and any side-to-side lean will distort the pressure reading considerably. It is best to over-inflate and then let the air out as there is a risk of loosing too much pressure when disconnecting the pump.

Agree with Spope. Slight slope can make a great difference. I also suggest that you carry a cycle pump or something similar when you are on your travels, and always check the pressure guages before starting each day.

A MAMIL I know has just kindly donated 2 of his bicycle pumps he no longer uses.  So I’ll be trying them out. 

I set them today using an electric pump and I think it was pretty level. I’ll have more idea on its next run out.  I don’t think they are leaking, so the advisory isn’t an immediate panic.

I just want to get out there now

P.S. do people really check the gauges each day?

Once you have had to change both( £450), bolts the wrong way , then a 5 second check is not a problem.

Tengah74 wrote:Once you have had to change both( £450), bolts the wrong way , then a 5 second check is not a problem.

That’s a very fair point, and to be fair I was thinking more of the need to adjust them, rather than a really quick visual check. That’s a good recommendation as the gauges are accessible and so visual as you board. 

Sally

Sally

After 5 years use, I check them when I think about it (not too often). Given that the balloons are airtight, they do not loose much air. Just make sure that you are on level ground when checking, otherwise you will be forever pumping them up and letting them down.

PS. Check pressure before using the van, or after an hour stationery, because like tyres, use will raise temperature and thus pressure.

The ever so slightly annoying thing, is that the mechanic took a few photos of where they had marked due to rubbing on the bolts.  I’ve asked him for a copy of them, so that I can see how bad they are (or aren’t) but he’s deleted them from his phone.

I’m going to have to throw on my dungarees and crawl under the van.  So I’ll wait for a sunny day, and until then I’ll just keep an eye on them.

Once I’ve got some photos, I’ll try and post them on here to get an opinion on how bad (or not) they are.  I need an independent comment about whether they are okay for now, or whether I need to get them fixed ASAP.

rgermain wrote:I think I recall seeing on here pictures of the offending bolts which can cause problems on earlier vans. Try doing a "alko" search.
------------
Richard

There’s quite a lot of info, but I couldn’t find a photo. I’ve seen one somewhere, but I can’t think where.

This the photo you want?

[You must be registered and logged in to see this link.]

V

Paulmold wrote:This the photo you want?

[You must be registered and logged in to see this link.]

That could be the one Paul, thank you for that. 

I assume that it is the bolts at the right and left that are rubbing on the rubber.  Does the photo show them fitted incorrectly, or correctly. If I know that, I know where to look on mine and I can show the garage. 

Unfortunately I haven't a clue, I don't have them on my Sussex.

The bolts punctured the airbags on our 2010 Symbol and were replaced under the extended warranty purchased from the supplying dealer, after we supplied evidence from helpful forum posts about this common problem.  Whether they were allowed to run flat I don't know.  But I don't think it has been pointed out on this thread that Alko have since redesigned the Air-Top units so there are no long bolts close to the bellows to chafe them.  We had the redesigned ones fitted as a straight swap and I notice these are also what are fitted to later model Autosleeper panel van conversions.  They have been trouble-free.

Sally, this photo shows the bolts fitted correctly.

Unfortunately, it is still possible for the bolt heads to contact the rubber air-bags.

Changing the bolts for a dome-headed type has been suggested.

G

[You must be registered and logged in to see this link.]

Changes my bolts for dome headed bolts from EBay. No problem, lots of clearance now.

Thank you to everyone for your help. I’m going to ask my garage man to change the bolts so that they are the other way, and use the dome ones mentioned above.

Sally

Well, I tried to see if the airbags could be replaced under warranty, but unsurprisingly there’s no joy there.  The warranty chaps have said that as they haven’t actually failed yet (as in completely blown) they are not covered.  Funnily enough they’ve just sent a letter asking if I want to take out another year’s cover.  I don’t think I’ll bother 


It’s definitely caused by the nuts and bolts fitted the wrong way around, so I’m going to ask my mechanic to change them for the dome headed ones mentioned on here.  Although the bellows are marked/rubbed they are definitely not leaking, so I’ll just keep my eye on it over the next 12 months.


Right, I’m off out to play at birdwatching with my new camera 

Sally

If AS  will not change the airbags, will they not at least change the nuts and bolts? This must rate as an original manufacturers fault and just because your 'van is 2011 does not change the facts. Is it not worth asking them to swap the bolts for the round-headed type?

Spospe wrote:Sally

If AS  will not change the airbags, will they not at least change the nuts and bolts? This must rate as an original manufacturers fault and just because your 'van is 2011 does not change the facts. Is it not worth asking them to swap the bolts for the round-headed type?

Hi - It’s not AS that have refused the warranty work by the way, it’s an aftermarket warranty provided with the used van when I bought it last year.  But I’m not sure that AS would be interested, or would admit any liability, even though it’s definitely an original fitting error. 

Even if they did,  the main problem is that it would probably cost me more to take the van there (and probably overnight camp fee as well) than getting my local garage to just change the bolts.  

I’ll check it out with ‘my man’ at the garage.  Hopefully he’ll know which of these dome head bolts to get. 

Sally