Bilstein B14 rear spring seating issue

[cheba]

Prior to installing my Bilstein B14 kit on my WRC, I noticed that the diameter of the uppermost coil was too small compared to the inner flange of the black adjustment collar. This was when the spring was held the correct way according to the Bilstein mounting instructions (text right side up). I had to double check the part number of the spring with the instructions to make sure they didn't include the wrong spring in my kit. Anyway, knowing Bilstein's good reputation I decided to put full trust in their instructions, and installed the springs. I then assumed that the uppermost coil would expand and pop in place when the spings were installed and loaded. However this was not the case.

Now only half of the uppermost coil is properly seated against the plastic ring. The other half is resting against the inner flange of the adjustment collar because the diameter of the coil is too small for it to seat properly. This is the case for both sides of the car.

There is however a difference between the different sides of the car. On the left side of the car it is the end of the coil which is seated against the plastic ring. On the right side of the car the end of the coil is resting against the inner flange of the adjustment collar. It is not until halfway into the first coil that the spring makes contact with the plastic flange. I tried unloading the right spring and turning it, trying to at least get the end of the coil to seat properly, but I was unsuccessful.

Also because of this, when I turn the adjustment collar on the right side of the car the end of the coil digs into the soft aluminium of inner flange of the adjustment collar, scraping it badly (small chips of aluminium are actually falling off as I turn the collar...)

I found this pic on the web of a 6R on B14's:

In the pic it looks like the spring is properly seated and the whole plastic ring is fully pressed against the adjustment collar (on my car the plastic rings are half loose because the spring isn't fully seated). However in the pic the spring is installed upside down compared to mine (mine are installed stiffer end down). So the spring in the pic is incorrectly installed according to Bilstein's mounting instructions, UNLESS my springs for some reason had the text printed upside down causing me to install them the wrong way, but that sounds like a far fetch...

Has anyone else with Bilsteins on their 6R ran into this problem? According to the mounting instructions, the parts for the rear axle are the some for all 6R Polos including the WRC.

I would appreciate input from any fellow B14/B16 users.

[cheba]

OK so I found another pic on the web:


The spring in this pic is installed the same way as mine. And if you look closely you can see that the blue plastic ring just below the adjustment collar seems to be pressed up against the adjustment collar on the left side (inside of the car), but hanging down a couple of millimeters on the right side (brake caliper side). This suggests that the uppermost coil is not completely seated against the plastic ring, which is exactly what I am experiencing with my kit.

It feels to me like it is not supposed to be like this. Design fault? Text printed the wrong way on the spring causing them to be installed the wrong way?

Mailing Bilstein for a technical inquiry. They don't seem to have a contact form or mail adress dedicated to tech support, so I don't know how much of a reply I will get.

Edit: Grammar

[alexperkins]

Those two springs are definately up different ways. It's possible the text was printed upside down. That's not necessarily an indicator of which way to install then

The thicker part of the coil normally sits to the bottom of the spring

[cheba]

Those two springs are definately up different ways. It's possible the text was printed upside down. That's not necessarily an indicator of which way to install then

The thicker part of the coil normally sits to the bottom of the spring

With this kit, the text indicates which way to install them. The mounting instruction says "Imprint is being on the head in installation situation" or in German "Aufdruck in Einbaulage auf dem Kopf stehend", both of which I can only interpret as "Install with text right side up". If the mounting instructions didn't say that, I would have installed them the other way, because of the seating issue I have when installed as per instructions. Although just out of curiosity, when holding the parts in my hand prior to installation I did try inserting the threaded adjuster in the other end of the spring, and it didn't feel like there was a perfect match. Coil diameter seemed to be a bit too large, so the fit was kind of loose.

May I ask what you mean by the thicker part of the coil? The spring is straight cylindrical so there is no thicker part. Only the last coil bend in each end is of smaller diameter than the rest of the spring.

Edit: Wait a minute. "on the head", that means upside down I guess.

[alexperkins]

By thicker I mean more closely wound. Bad choice of terminology on my part

I would say they need to be the other way up

The translation does refer to upside down which implies the text has to be upside down

"Imprint in erection standing upside down" - granted that's a rather literal translation.

[cheba]

By thicker I mean more closely wound. Bad choice of terminology on my part

I would say they need to be the other way up

The translation does refer to upside down which implies the text has to be upside down

"Imprint in erection standing upside down" - granted that's a rather literal translation.

Yeah, it just dawned on me as I read it for like the 20th time. I was thinking: "on the head", what are you when you are standing on your head? You are upside down. Of course.

I guess the first time I read it I just dismissed it as a bad translation. I assumed that the "on the head" part simply meant "up" -> "print up" -> "print right side up". But I guess the "auf dem Kopf stehend" is how it's said in German, and "on the head" is a literal translation.

Oh well, I guess I just have to switch them around as soon as I get the chance.

[iichel]

On the head is indeed upside down

[cheba]

On the head is indeed upside down

Yes. I guess that since English is not my first language, I didn't make that connection right away. I've never used the phrase "on the head" when talking/writing in English, I always use "upside down". But it makes sense.

[iichel]

Haha my mother tongue is Dutch, we learn English quite early (around the age of 10) and German is by daily tongue since I live in Switzerland.

https://youtu.be/sNj8mJq65i4?t=2m27s