2002 Mercedes-Benz S430 4.3L Eng VIN _NA_ Print Date: 7/23/2018 Safety Precautions

Safety Information: Suspension - AS32.00-Z-9999ZZ

MODEL all

Risk of death caused by lowering vehicle when working between wheels and body. MODEL AS32.22-Z- Risk of injury caused by pinching or jamming when working on the air suspension. all 0001-01A

General Notes: Passenger Cars: Suspension - AH32.00-Z-9999AZ

MODEL all

AH32.22-P- Special information on AIRmatic MODEL 164... 1000-02GZ

AH32.22-P- Special information on AIRmatic MODEL 240 1000-02H

AH32.22-P- Special information on AIRmatic MODEL 251 1000-02RT

AH32.22-P- Notes on AIRmatic MODEL 221, 216 1000-02SX

Notes on checking oil level on vehicles AH32.00-P- MODEL all... with level control/ADS 0003-01A

Springs; general background MODEL 129, 140, 170, 171, 202, 203, 208, 209, AH32.20-P- information. 210, 211, 219, 230... 9404-01A

Notes on Active Body Control AH32.50-P- MODEL 215, 216, 220, 221, 230... suspension 0001-01N

MODEL 220 except CODE (487a) Active body AH32.22-P- Notes on AIRmatic control (ABC) 1000-02I

General notes on working on vehicles AH32.00-P- MODEL all... with level control/ADS 0002-01A

MODEL 211.2 except CODE (489) Airmatic (semi- AH32.22-P- Notes on air suspension active air suspension) MODEL 211.6 1000-01T

MODEL 211.0/2, 219 with CODE (489) Airmatic AH32.22-P- Special information on AIRmatic (semi-active air suspension) 1000-02T

Observe removal and installation MODEL 210 with CODE (217a) Level Control at AH32.32-P- position of shock absorber/ADS Rear Axle with ADS 0001-01A

General notes on repair work on vehicles MODEL 129, 140, 210 with CODE (217a) Self- AH32.32-P- with ADS levelling suspension on rear axle with ADS 9406-01A

AH32.50-P- Notes on fitting hydraulic lines and hoses MODEL 215, 216, 220, 221, 230... 0001-02A

Miscellaneous Notes

Disposing Of Spring Strut - OS32.25-P-0122

Disposing Of Spring Strut - OS32.25-P-0122-01I

Risk of injury when drilling gas-filled assemblies or Wear safety goggles and AS00.00-Z- components (gas filling cannot ignite) face mask. 0006-01A

Model 220

Front axle spring strut:

1. Drill a hole in the spring strut from above in area (D) with a 5mm dia. drill bit and allow the air to escape.

2. Drill a hole in the spring strut 30mm (dimension A) from the bottom with a 5mm dia. drill bit and allow the gas to escape.

3. Drill a hole in the spring strut 90mm (dimension B) from the bottom with a 5mm dia. drill bit and allow the hydraulic fluid to escape.

4. Drill a hole in the spring strut 140mm (dimension C) from the bottom with a 5mm dia. drill bit (1st and 2nd walls) and allow the hydraulic fluid to escape.

5. Pump the spring strut empty by pressing in the piston rod several times.

6. Dispose of spring strut (scrap).

Observe regulations governing disposal of hydraulic fluid. Fig 1: Identifying Hole Area On Front Spring Strut

Disposing Of Spring Strut - OS32.25-P-0122-01J

Risk of injury when drilling has-filled assemblies or Wear safety goggles and AS00.00-Z- components (gas filling cannot ignite) face mask. 0006-01A

Model 220

Rear axle spring strut:

1. Drill a hole in the spring strut from above in area (H) with a 5mm dia. drill bit and allow the air to escape.

2. Drill a hole in the spring strut 80mm (dimension E) from the bottom with a 5mm dia. drill bit and allow the gas to escape.

3. Drill a hole in the spring strut 135mm (dimension F) from the bottom with a 5mm dia. drill bit and allow the hydraulic fluid to escape.

4. Drill a hole in the spring strut 200mm (dimension G) from the bottom with a 5mm dia. drill bit (1st and 2nd walls) and allow the hydraulic fluid to escape.

5. Pump the spring strut empty by pressing in the piston rod several times.

6. Dispose of spring strut (scrap).

Observe regulations governing disposal of hydraulic fluid. Fig 2: Identifying Hole Area On Rear Spring Strut

Dispose Of Suspension Strut. - OS32.25-P-0122-01N

Risk of injury to skin or eyes from hydraulic Depressurize the hydraulic system completely AS00.00-Z- fluid spraying out under pressure. Risk of before starting any work on the system. Wear 0013-01A poisoning from swallowing hydraulic fluid. protective clothing and safety glasses.

Risk of injury caused by drilling gas-filled AS00.00-Z- assemblies or components (noncombustible Wear safety glasses and a face mask. 0006-01A gases)

Observe regulations governing disposal of hydraulic fluid.

1. By scanning check whether the spring cup abuts the upper stop (arrow) and cut open boot (40e) if necessary.

Front axle suspension strut shown Fig 3: Locating Upper Stop

2. Detach hydraulic line (40f) carefully from the suspension strut (due to residual pressure).

3. Empty the hydraulic line (40f); to do this, press on the nipple (arrow) of the quick-release coupling and dispose of the hydraulic line (40f).

4. Place suspension strut with the hydraulic line connection downwards in a suitable vessel and allow the hydraulic fluid to run out (drainage time at least 5 minutes).

Front axle suspension strut shown Fig 4: Locating Nipple And Hydraulic Line

Front axle suspension strut

5. Drill out suspension strut (40) in the area A through the outer and inner wall (twin-tube damper) and allow gas to escape. (dimension: 40 mm, drill diameter: 5 mm)

6. Drill out suspension strut below the spring cup (area B) (max. 13 mm deep, drill diameter: 5 mm) and allow hydraulic fluid to drain out. Fig 5: Identifying Drill Area Below Front Spring Cap

Rear axle spring strut

7. Drill out suspension strut (41) in the area A through the outer and inner wall (twin-tube damper) and allow gas to escape. (dimension a: 75 mm, drill diameter: 5 mm).

8. Drill out suspension strut in the area B and allow hydraulic fluid to run out. (dimension b: 7 mm, drill diameter: 5 mm). Fig 6: Identifying Drill Area Below Rear Spring Cap

Disposing On Spring Actuator - OS32.30-P-0620-01A

Risk of injury to skin or eyes from hydraulic Depressurize the hydraulic system completely AS00.00-Z- fluid spraying out under pressure. Risk of before starting any work on the system. Wear 0013-01A poisoning from swallowing hydraulic fluid. protective clothing and safety glasses.

Risk of injury caused by drilling gas-filled AS00.00-Z- assemblies or components (noncombustible Wear safety glasses and a face mask. 0006-01A gases)

1. Allow hydraulic fluid or brake fluid to flow out of the oil gallery (a) into a suitable container for disposal.

2. Drill gas chamber (b) of the spring accumulator on the arched side (arrow) with a drill bit (3 mm dia.) until the gas flows out.

3. Dispose of spring brake reservoir as scrap metal. Fig 7: Identifying Spring Accumulator On Arched Side

Fig 8: Locating Gas Chamber & Oil Gallery

Notes On AIRmatic - AH32.22-P-1000-02I

Model 220 Fig 9: Identifying AIRmatic Components Location

Fig 10: Identifying AIRmatic Connection

• Before removal, depressurize AIRmatic components (spring struts, valve unit, central reservoir) using Star Diagnosis and empty complete system if necessary. The components or the complete system must not be emptied by unscrewing pressure lines. • Clean dirty pressure pipe connections before unscrewing. Do not use any cleaning agents/solvents as pressure lines might be damaged as a result.

Seal pressure pipes and connections on the components immediately with blind plugs.

• Only use an open box wrench or special tool to unscrew pressure lines. • Spring struts which have been removed or are not tightened securely must not be filled with compressed-air and not pushed together. • When installing spring struts ensure that residual pressure valves, protective boots and ADS valves with electrical connections are not damaged. • Spring struts must not be loaded between installing the spring struts and filling the system (no spring movement). • Before driving into automatic car washes, onto pits, hoists or on very uneven roads, set raised vehicle level on the vehicle level switch. The high level is reached when the "Air spring - vehicle lifting up" display on the multifunction display goes out. • When the vehicle is parked for a prolonged period turn the wheels straight-ahead as pressure loss may occur. • Emergency running buffers used on the spring struts for transport or shipping are available through the spare parts channels.

The emergency-running buffers may only be used for maneuvering

Notes On Suspension - AH32.50-P-0001 Notes On Active Body Control Suspension - AH32.50-P-0001-01N

Fig 11: Identifying Active Body Control Suspension Components Location (Shown On Model 215)

Shown on model 215

Fig 12: Identifying Active Body Control Suspension Components Location (Shown On Model 230)

Shown on model 230

• Always clean the area adjacent to the connections and hose fittings on any and all components being removed prior to starting repair work on ABC systems.

Use caution to ensure that residue and contaminants from repair operations, such as metal shavings, lint, etc., do not enter the ABC system through connections and hose fittings.

• Use the bleed screw (56, 57) to drain the hydraulic fluid, then dispose of the fluid according to regulations.

To prevent the body from dropping too quickly, open bleed screws (56, 57) carefully to limit the flow of the emerging hydraulic fluid.

• Because even minute particles and traces of contaminants can lead to ABC failure, always pay scrupulous attention to cleanliness when adding hydraulic fluid! • When bleeding air from the ABC system, and whenever allowing the pump motor to run, always ensure that the fluid reservoir (2) contains an adequate supply of hydraulic fluid, and verify that the tandem pump (1) is not ingesting air. • Adding hydraulic fluid.

The funnel with filter must not be used with other service fluids. To help prevent damage due to dirt entering the ABC system, always store this filter-equipped funnel in a separate cabinet.

• The ABC fluid-return circuit contains a distribution valve with a booster valve and a temperature sensor. • Before leaving the vehicle parked for extended periods, always bring the front road wheels to their straight-ahead position. Should the ABC system subsequently suffer an internal pressure loss, this precaution will protect vehicle bodywork against contact and possible damage stemming from contact with front wheels that are turned to an angle. Notes On Fitting Hydraulic Lines And Hoses - AH32.50-P-0001-02A

Due to the extremely high pressures in the ABC system, proceed with great care when assembling hydraulic lines and hoses. Otherwise leaks can occur which can lead to accidents, damage to the vehicle as well as environmental pollution.

• Check sealing surfaces and any union nuts of the hydraulic lines and hoses as well as sealing surfaces and connections of ABC system components for damage before assembly and replace defective components if necessary. • Before assembly clean sealing surfaces, connections and any union nuts thoroughly. Do not use anything other than compressed air and lint-free cloths for this operation. • Replace sealing rings and O-rings. • In the case of sealing rings with support ring the sealing ring should only be replaced in the event of damage. If the support ring is damaged the complete hydraulic line should be replaced. • Align hydraulic lines and hoses with their connections free from tension. • As far as possible tighten any union nuts by hand. • Pay attention to tightening torques.

Removal & Installation

Check Pressure Line With High Pressure Flexible Hose On Damper Strut - SM32.50-P-0001A

MODEL 215.### ## up to 008152

MODEL 220.07# /170 /173 /175 ## up to 139486 with CODE (487a) Active body control (ABC)

MODEL 220.178 ## up to 139486

Fig 13: Checking Clearance Between ABC Hydraulic Line And Rearaxle Damper Strut Fig 14: Identifying Pipe Bend Direction

OPERATION NO. OF OPERATION TEXTS OR STANDARD TEXTS AND FLAT RATES

Op. Acc. Sector Operation text Time Code no. no.

P 023353 CHECK ABC HYDRAULIC LINE CLEARANCE ON REAR AXLE 3 WU/0.25 h

P 023354 REWORK ONE HYDRAULIC LINE ON REAR AXLE 4 WU/0.3h

6 work P 023355 REWORK BOTH HYDRAULIC LINES ON REAR AXLE units/0.5 h

REPLACE ONE ABC HYDRAULIC LINE ON REAR AXLE P 023358 54 WU/4,5 h FOLLOWING INSPECTION

REPLACE BOTH ABC HYDRAULIC LINES ON REAR AXLE P 023359 62 WU/5,2 h FOLLOWING INSPECTION

P 023356 REPLACE ONE REAR ABC DAMPER STRUT 18 WU/1.5 h

P 023357 REPLACE BOTH REAR ABC DAMPER STRUTS 34 WU/2,8 h

Depressurize the hydraulic system Risk of injury to skin or eyes from hydraulic fluid completely before starting any work on the AS00.00-Z- spraying out under pressure. Risk of poisoning system. Wear protective clothing and safety 0013-01A from swallowing hydraulic fluid. glasses.

AH32.50-P- Notes on ABC-suspension 0001-01N

1 Raise the vehicle on lifting platform

There must be a minimum clearance of 5 mm. between the ABC hydraulic line and the Check ABC hydraulic line routing on rear axle rearaxle damper strut (dimension x in Fig 2 damper strut 13). If clearance is less than that ↓

Remove road wheel on the affected vehicle side ↓ AP40.10-P- Bend the pipe down with your hand in the 4050Z direction of the arrow in Fig 14 until a clearance of approx. 5-10 mm has been created (confer dimension x in Fig 14).

Check high pressure flex-hose and protective If chafing marks are visible: 3 boot on damper strut for any chafing spots ↓

Remove road wheel on the affected vehicle AP40.10-P- side 4050Z ↓ If the high pressure flex-hose reveals the metal webbing below its plastic outer layer: ↓

Replace pressure line with high pressure flexible hose ↓ AR32.50-P- If protective boot around damper strut is 1165-01A chafed through: ↓

AR32.25-P- Remove, replace, and install damper strut 1016N

Risk of accident from vehicle starting off by itself Secure vehicle to prevent it from moving off when engine running. Risk of injury from AS00.00-Z- by itself. Wear closed and tight-fitting work contusions and burns if you insert your hands into 0005-01A clothes. Do not grasp hot or rotating parts. the engine when it is started or when it is running

Fill up and vent the Active-Body-Control (ABC) AR32.50-P- 4 system 0021N

5 Check system for leakage

PARTS ORDERING NOTES

Part no. Designation Quantity

001 989 24 03/10 Hydraulic oil as required

220 997 09 82 Left line as required

220 997 08 82 Right line as required

220 990 00 04 Axle carrier mounting bolts as required

Flushing Active Body Control (ABC) System - SM32.50-P-0002A

MODEL 215.### #A as of 018130 up to 023610, 220.### #A as of 227562 up to 265219, 230.### #F as of 000300 up to 004810 with CODE (487) Active Body Control (ABC)

OPERATION NO. OF OPERATION TEXTS OR STANDARD TEXTS AND FLAT RATES

Category Op. no. Operation text

P 023476 FLUSHING ABC SYSTEM AND CHECKING FOR PROPER FUNCTION, MODEL 215

P 023474 FLUSHING ABC SYSTEM AND CHECKING FOR PROPER FUNCTION, MODEL 220

P 025121 FLUSHING ABC SYSTEM AND CHECKING FOR PROPER FUNCTION, MODEL 230

P 023477 CHECK ABC SYSTEM FOR PROPER OPERATION (AFTER 12 HOURS), MODEL 215

P 023475 CHECK ABC SYSTEM FOR PROPER OPERATION (AFTER 12 HOURS), MODEL 220

P 025122 CHECK ABC SYSTEM FOR PROPER OPERATION (AFTER 12 HOURS), MODEL 230

It is absolutely necessary to follow the described procedure!

During the entire procedure pay attention to extreme cleanliness to avoid dirt getting into the system!

1 Connect STAR diagnosis If necessary erase ABC fault memory.

2 Start engine Position wheels straight ahead.

In DAS menu: Select "Rodeo" function in DAS, Control units/chassis/suspension/actuations Cyclically changing 3 start with function key F3 and actuation of all spring struts in circle (Rodeo). allow to run for 15 minutes. This heats the hydraulic oil up to approx. 80 °C.

4 Turn off engine

Remove return line from ABC oil 5 reservoir and route to suitable Minimum capacity: 15 l catch vessel

Remove return filter from oil 6 reservoir

In DAS menu: //actuations 7 Select "Pitch" in DAS function Cyclically changing actuations of front and rear spring struts (pitching).

8 Start engine Oil exits from return line.

Start DAS function "Pitch" with 9 Vehicles lifts/lowers alternately at front and rear. function key F3

10 Observe oil level in oil reservoir As soon as the oil reservoir is 3/4 empty refill with oil. Use a funnel which is absolutely clean (do not bring funnel into contact with a fluffy rag and store in a clean protective foil after use). Do not use normal ABC filler funnel with filter, because it does not allow the required quantity of oil to flow through. Pump should never run dry. If pump is in danger of running dry, shut off engine, add oil and go back to step 8.

11 Flush Flush until 10 l of new oil have been added.

12 Turn off engine

SM32.50-P- 13 Replacing oil filter 0002-01A

14 Close oil reservoir

15 Install return line

Check oil level in reservoir and 16 For filling and correcting use measuring opening. correct, if necessary

Check ABC system for proper SM32.50-P- 17 STAR diagnosis must be connected. function 0002-02A

PARTS ORDERING NOTES

Part no. Designation Quantity

001 989 24 03 10 ABC hydraulic fluid, Pentosin (1 l) 10

003 184 51 01 ABC oil filter 1

Removing And Installing Oil Filter - SM32.50-P-0002-01A

1. Unhook spring by pressing (arrow).

2. Remove oil filter. Fig 15: Unhooking Spring

3. Install new oil filter.

Hook in spring. Ensure that the rubber sealing ring above the filter is not canted. Fig 16: Installing Oil Filter

Checking Active Body Control System (ABC) For Proper Function - SM32.50-P-0002-02A

1. Start vehicle

2. Allow vehicle to run for 10 minutes with DAS function "Rodeo".

Vehicle at normal level

3. Lift level to stage 2 by actuating level switch.

Both LED's in the level switch come on.

4. Allow vehicle to idle for 15 minutes in level stage 2

Do not move vehicle and do not change level.

5. Lower level to normal position by actuating level switch.

Do not enter the vehicle, otherwise the control valves actuate immediately.

Both LED's in the level switch go out.

Evaluation:

Visual check with 2nd employee standing outside.

The level control should start immediately and the vehicle should lower uniformly.

(A delay of max. 1 s between left/right and front/rear is no reason for complaint).

Vehicle not okay: ↓

6. Allow vehicle to stand over night.

At least 12 hours.

7. Check again.

Without "Rodeo", start with step 3.

Vehicle not okay: ↓

8. Reflush ABC system.

Information to:

GSP/SPP

Tel.: +49 (0) 711-17-63867

Eliminate Line Leakage At Valve Unit - SM32.50-P-0004A

MODEL 215

MODEL 220 with CODE (487a) Active body control (ABC)

MODEL 230 with CODE (487a) Active body control (ABC)

OPERATION NO. OF OPERATION TEXTS OR STANDARD TEXTS AND FLAT RATES Op. Acc. Range Operation text Time Code no. no.

Active Body Control (ABC)- check system for Time prescribed by P 327490 - - leaks foreperson

MODIFICATION NOTES

Value changed from 50 Nm to 45 Value in series 1001, 1002,1003, 1012 line 1 and 2, 1013 modified for 5.3.03 Nm model 230

Risk of injury to skin or eyes from hydraulic fluid spraying out Release the pressure in the hydraulic system completely AS00.00-Z- under pressure. Risk of before starting any work on the system. Wear protective 0013-01A poisoning from swallowing clothing and safety glasses. hydraulic fluid.

Wait for pressure relief in ABS system. Pressure is relieved 10 minutes after engine is shut down so that the Loosen leaky line, center and ABC high pressure line can be opened. 1 tighten without tension to 50...55 It is only possible to ensure that the line connections are Nm properly tightened when they are positioned tension-free with particular care (tighten nuts as far as possible without using tool) and then tighten to specified torque.

*BA32.50-P- Union nut, line to pressure reservoir 1001-01A

*BA32.50-P- Union nut, line to front/rear axle valve unit 1002-01A

*BA32.50-P- Union nut, line to distributor 1003-01A

*BA32.50-P- Union nut, line to pressure supply valve unit 1012-01A

For this purpose:

◦ Clean leaky point.

◦ Spray line/component with leak detection spray.

◦ Connect STAR DIAGNOSIS.

◦ Select menu item "Actuation" in the ABC system and allow the vehicle to run for at least 10 min in the "Rodeo" program (whereby the system heats up to reach operating temperature).

◦ Perform visual check.

If the system is still leaky: ↓ Remove/install/replace leaky lines. Check system for leakage For this purpose:

◦ Clean leaky point. 2 Check system for leakage ◦ Spray line/component with leak detection spray.

◦ Allow vehicle to run for at least 5 min in the "Rodeo" program.

◦ Perform visual check.

If the system is still leaky: ↓ Remove/install/replace the corresponding counterpiece for the line terminal (e. g. valve block, T-piece) Check system for leakage For this purpose:

◦ Clean leaky point.

◦ Spray line/component with leak detection spray.

◦ Allow vehicle to run in the "Rodeo" program for a further 5 minutes.

◦ Perform visual check.

ACTIVE BODY CONTROL SUSPENSION Number Designation Model 215 Model 220 Model 230

BA32.50-P-1001-01A Union nut, line to pressure reservoir NM 50 50 45

BA32.50-P-1002-01A Union nut, line to front/rear axle valve unit NM 50 50 45

BA32.50-P-1003-01A Union nut, line to distributor NM 50 50 45

M14 NM 50 50 45 BA32.50-P-1012-01A Union nut, line to pressure supply valve unit M16 NM 50 50 45

Remove/Install Front Center Assembly Suspension On Rear Axle Carrier - AR35.10-P-0051

Remove/Install Front Center Assembly Suspension On Rear Axle Carrier - AR35.10-P-0051I

MODEL 215.375 /378, 220.025 /026 /028 /063 /065 /067 /070 /075 /083 /084 /087 /126 /128 /165 /167 /170 /175 /178 /183 /184 /187

Fig 17: Identifying Front Center Assembly Suspension On Rear Axle Carrier Remove/Install Components - Model 215.375

Remove/Install

Align vehicle between the columns of the lifting platform and position the four Risk of death. Death may result if vehicle slips or AS00.00-Z- support plates at the lifting platform topples off the lifting platform 0010-01A support points specified by the vehicle manufacturer.

While working on the rear axle care must be taken to ensure that the surface of all aluminum components do not get any scratches, cracks and notches. Otherwise the service life of the parts will be affected

AH00.00-N- Notes on self-locking nuts and bolts 0001-01A

1 Raise vehicle.

Use assembly attachment, pit hoist or floor jack to 2 Assembly attachment Figure support rear axle center assembly.

Installation: When tightening the bolt, 3 Unscrew bolt (51a) counterhold front rear axle center assembly suspension (51) at square.

*BA35.10-P- 1002-04A

4 Remove washer (51b)

Installation: Put bolt (51a) on before 5 Unscrew nut (51c) tightening.

*BA35.10-P- 1001-04A

Remove front rear axle center assembly 6 suspension (51)

7 Install in the reverse order

FRONT CENTER ASSEMBLY SUSPENSION Models 220.025/026/ 028 /063/065/ Model 067/070/073/ 075/083/084/ 087/125/126/ Number Designation 215.373/ 128/165/167/ 170/173/175/ 375/378 178/183/184/187

Self-locking nut, front center BA35.10-P- assembly suspension to rear Nm 120 120 1001-04A axle carrier

Self-locking bolt, rear axle yellow Nm 45 45 BA35.10-P- center assembly to front silver or 1002-04A Nm 60 60 center assembly suspension blue

Fig 18: Identifying Assembly Attachment (140 589 01 62 00)

Remove/Install Front Center Assembly Suspension On Rear Axle Carrier - AR35.10-P-0051M

MODELS 215.374/ 376/ 379

MODELS 220.074 /174 /176 /179

Fig 19: Identifying Front Center Assembly Suspension On Rear Axle Carrier Remove/Install Components - Model 215.374/376

Remove/Install

Risk of death caused by vehicle slipping or toppling Align vehicle between the columns of the AS00.00-Z- off of the lifting platform. hydraulic hoist and position the four 0010-01A support plates below the hoist support points specified by the vehicle manufacturer.

While working on the rear axle care must be taken to ensure that the surface of all aluminum components do not get any scratches, cracks and notches. Otherwise the service life of the parts will be affected

AH00.00-N- Notes on self-locking nuts and bolts All models 0001-01A

AR49.10-P- 1.1 Remove exhaust system as of flange connection Engine 275.950 7280M

Refer to Removing exhaust system complete: ↓

AR49.10-P- Engine 113 7000AA

Engine 275.980 in model 215.379, AR49.10-P- 1.2 Remove rear muffler 220.179 4951IM

2 Support rear axle center assembly (1) assembly top Figure

Detach front center assembly suspension (7) from *BA35.10-P- 3 rear axle center assembly (1); for this purpose, 1001-04A remove bolted connection (8)

Remove bolted connection (10) and front center *BA35.10-P- 4 assembly mount (7) 1003-04A

5 Install in the reverse order

FRONT CENTER ASSEMBLY MOUNT

Model Model Number Designation 215.374/376/379 220.074/174/176/179

BA35.10-P- Self-locking nut, front center assembly Nm 120 120 1001-04A mount to rear axle carrier

1st Self-locking bolt, rear axle center Nm 100 100 BA35.10-P- stage assembly to front center assembly 1003-04A 2nd mount ∠° 180 180 stage

Fig 20: Identifying Assembly Top For Mounting Rear Axle Gear (240 589 00 62 00)

Testing & Repair Remove/Install Limp-Home Buffers - AR32.00-P-1000I

MODEL 220, 215

Fig 21: Identifying Limp-Home Buffers Remove/Install Components (Shown On Model 220)

Shown on MODEL 220

Remove/install

AH32.22-P- Special information on AIRmatic 1000-02I

The limp-home buffers may only be used for maneuvering

1 Raise corresponding side of vehicle

Front axle

Mount limp-home buffer (1a) onto upper transverse control Limp-home buffer part number: 2 arm (6) A 220 327 12 30

Slowly lower vehicle and make sure that the limp-home 3 buffer makes contact with top of wheelhouse

Rear axle

The body fold must lie in the groove of the limp-home buffer. Slide limp-home buffer (1b) in between body fold and 4.1 For vehicles with AIRmatic only torsion bar (77) Limp-home buffer part number: A 220 328 08 39

Slowly lower vehicle and make sure that the torsion bar 5.1 Only on vehicles with AIRmatic (77) makes contact with the limp-home buffer (1b)

6 Remove in reverse order

Testing And Repair Work: Passenger Cars: Suspension - AR32.00-Z-9215AA

MODEL 215

AR32.00-P- Remove/install limp-home buffers MODEL 220, 215 1000I

MODEL 215 MODEL 220 with CODE (487) Active AR32.25-P- Remove/install rear suspension strut Body Control (ABC) 1016N

AR32.25-P- Remove/install the suspension strut MODEL 215, 220 ... 1017N

Replace rubber mounts of rear shock MODEL 215 MODEL 220 except CODE (Z07) Top AR32.25-P- absorbers protection except CODE (Z04) Light armoring 1871M

AR32.50-P- Remove/install front axle valve body MODEL 215, 220 ... 0001N

AR32.50-P- Remove/install rear suspension valve body MODEL 215, 220 ... 0002N

Valve body in pressurization circuit, removal AR32.50-P- MODEL 215, 220 ... and installation 0003N

Remove/install hydraulic line (ABC) of tandem MODEL 220.178, 215.378 with ENGINE 137.970 AR32.50-P- pump to pressure supply valve unit with CODE (487a) Active body control (ABC) 0004M

Remove/install hydraulic line MODEL 215, 220 ... AR32.50-P- 0005M

Remove/install front suspension pressure AR32.50-P- MODEL 215, 220 ... reservoir 0010N

AR32.50-P- Remove/install rear axle pressure reservoir MODEL 215, 220 ... 0011N

AR32.50-P- Remove/install return pressure reservoir MODEL 215, 220 ... 0012N

AR32.50-P- Remove/install pulsation damper MODEL 215, 220 ... 0013N

Remove/install pressure sensor for Active AR32.50-P- MODEL 215, 220 ... Body Control 0014N

AR32.50-P- Remove/install oil cooler MODEL 215, 220 ... 0020N

Fill up and vent the Active-Body-Control (ABC) AR32.50-P- MODEL 215, 220, 230 ... system 0021N

Remove/install control unit (ABC) (Active Body MODEL 215, 220 with CODE (487a) Active body AR32.50-P- Control) control (ABC) 0023I

MODEL 215, 216, 220, 221, 230 with CODE (487) AR32.50-P- Filter Active Body Control (ABC) hydraulic fluid Active Body Control (ABC) 0025A

MODEL 215, 216, 220, 221, 230 with CODE (487) AR32.50-P- Flushing active body control (ABC) system Active Body Control (ABC) 0026A

Testing And Repair Work: Passenger Cars: Suspension - AR32.00-Z-9220AA

MODEL 220

AR32.00-P- Remove/install limp-home buffers MODEL 220, 215 1000I

MODEL 220.175 /178 with CODE (Z07) Top AR32.20-P- Remove/install rear spring protection 0230MB

MODEL 220 (except 220.083 /084 /087 /183 /184 AR32.20-P- Remove/install stabilizer bar on front axle /187) except CODE (487) Active body control (ABC) 0300I

AR32.20-P- Remove/install torsion bar on front axle MODELS 220.083 /084 /087 /183 /184 /187 0300IW

MODEL 220.175 /178 with CODE (Z07) Top AR32.20-P- Remove/install torsion bar on front axle protection 0300MB

AR32.20-P- Remove/install torsion bar on front axle Models 220.875 /878 0300MP

AR32.20-P- Install new stabilizer bar pivot bushing MODEL 211, 220, 230 ... 0310M

MODEL 220 except CODE (487) Active Body AR32.20-P- Remove/install stabilizer bar on rear axle Control (ABC) 0315I

MODEL 220.175 /178 with CODE (Z07) Top AR32.20-P- Remove/install stabilizer bar on rear axle protection 0315MB

AR32.20-P- Remove/install stabilizer bar on rear axle MODEL 220.875/ 878 0315MP

MODEL 220 except CODE (487) Active body control AR32.22-P- Seal top air suspension strut (ABC) 1600I

MODEL 220 except CODE (487) Active Body AR32.22-P- Remove compressor, install Control (ABC) 2001I

Removing and installing AIRmatic central MODEL 220 except CODE (487) Active Body AR32.22-P- reservoir Control (ABC) 2017I

MODEL 220 except CODE (487a) Active body AR32.22-P- Remove/install air suspension control unit control (ABC) 6000I

MODEL 220 except CODE (487a) Active body AR32.22-P- Inspecting AIRmatic for leaks control (ABC) 8100I

MODEL 220 except CODE (487) Active Body AR32.25-P- Remove/install rear suspension strut Control (ABC) 1016I

MODEL 220.175 /178 with CODE (Z07) Top AR32.25-P- Remove/install rear suspension strut protection 1016MB

AR32.25-P- Remove/install rear suspension strut MODELS 220.875 /878 1016MP

MODEL 215 MODEL 220 with CODE (487) Active AR32.25-P- Remove/install rear suspension strut Body Control (ABC) 1016N

Remove/install the suspension assembly MODEL 220 ... AR32.25-P- 1017I

AR32.25-P- Remove/install the suspension assembly MODEL 220.083 /084 /087 /183 /184 /187 1017IW

MODEL 220 with CODE (979) Special protection AR32.25-P- Remove/install the suspension strut version with CODE (Z07) Top protection 1017MB

AR32.25-P- Remove/install the suspension strut MODEL 220.8 1017MP

AR32.25-P- Remove/install the suspension strut MODEL 215, 220 ... 1017N

Replace rubber mounts of rear shock MODEL 215 MODEL 220 except CODE (Z07) Top AR32.25-P- absorbers protection except CODE (Z04) Light armoring 1871M

Removing and installing level control valve MODEL 220 except CODE (487) Active Body AR32.31-P- unit Control (ABC) 0650I

AR32.50-P- Remove/install front axle valve body MODEL 215, 220 ... 0001N

AR32.50-P- Remove/install rear suspension valve body MODEL 215, 220 ... 0002N

Valve body in pressurization circuit, removal AR32.50-P- MODEL 215, 220 ... and installation 0003N

Remove/install hydraulic line (ABC) of MODEL 220.178, 215.378 with ENGINE 137.970 AR32.50-P- tandem pump to pressure supply valve unit with CODE (487a) Active body control (ABC) 0004M

AR32.50-P- Remove/install hydraulic line MODEL 215, 220 ... 0005M

Remove/install front suspension pressure AR32.50-P- MODEL 215, 220 ... reservoir 0010N

AR32.50-P- Remove/install rear axle pressure reservoir MODEL 215, 220 ... 0011N

AR32.50-P- Remove/install return pressure reservoir MODEL 215, 220 ... 0012N

MODEL 220.176 except CODE (979) Special AR32.50-P- Remove/install pulsation damper protection version 0013M

AR32.50-P- Remove/install pulsation damper MODEL 215, 220 ... 0013N

Remove/install pressure sensor for Active AR32.50-P- MODEL 215, 220 ... Body Control 0014N

AR32.50-P- Remove/install oil cooler MODEL 215, 220 ... 0020N

Fill up and vent the Active-Body-Control AR32.50-P- MODEL 215, 220, 230 ... (ABC) system 0021N

Remove/install control unit (ABC) (Active MODEL 215, 220 with CODE (487a) Active body AR32.50-P- Body Control) control (ABC) 0023I

Filter Active Body Control (ABC) hydraulic MODEL 215, 216, 220, 221, 230 with CODE (487) AR32.50-P- fluid Active Body Control (ABC) 0025A

MODEL 215, 216, 220, 221, 230 with CODE (487) AR32.50-P- Flushing active body control (ABC) system Active Body Control (ABC) 0026A

Clamping Rear Spring - AR32.20-P-0200-06MB

Risk of injury cause by Use only approved tensioning devices; crushing when pinching or crushing when working on springs or spring shield off hazard area if AS00.00-Z- working on springs or spring necessary. bodies that are under load Inspect special tools 0001-01A bodies that are under load for damage and proper operation (visual inspection).

wear protective gloves Fig 22: Identifying Tensioning Device (202 589 01 31 00)

Fig 23: Identifying Tensioning Plates (202 589 13 63 00)

The retaining lugs (arrow) must always engage in the recesses in the upper clamping plate. Fig 24: Identifying Retaining Lugs

Installed state

1. Insert upper clamping plate (01b) into rear spring (73) such that approx. 3 coils remain exposed above.

2. Position lower clamping plate (01c) on spring control arm (72) from below.

3. Insert tensioning device (01a) into clamping plates (01b, 01c) from below through spring control arm (72) and secure to upper clamping plate (01b).

4. Tension rear spring (73).

Do not use an impact wrench.

Fig 25: Identifying Rear Spring, Clamping Plate And Tensioning Device Removed state

5. Insert rear spring (73) into spring control arm (72).

6. Insert upper clamping plate (01b) into rear spring (73) such that approx. 3 coils remain exposed above.

7. Position lower clamping plate (01c) on spring control arm (72) from below.

8. Insert tensioning device (01a) into clamping plates (01b, 01c) from below through spring control arm (6) and secure to upper clamping plate (01b). Fig 26: Identifying Clamping Plate, Spring Control Arm And Tensioning Device

9. Align rear spring (73) with spring control arm (72).

The hole (arrow) in the impression on the spring control arm must be exposed.

10. Tension rear spring (73).

Do not use an impact wrench.

Fig 27: Locating Hole On Spring Control Arm Remove/Install Rear Spring - AR32.20-P-0230MB

MODEL 220.175 /178 with CODE (Z07) Top protection

Fig 28: Identifying Rear Spring Remove/Install Components

Remove/Install

Align vehicle between the columns of the lifting Risk of death cased by vehicle platform and position the four support plates at the AS00.00-Z- slipping or toppling off of the lifting lifting platform support points specified by the 0010-01A platform. vehicle manufacturer.

Use only approved clamping devices; shield off Risk of injury caused by pinching hazard area if necessary. Inspect special tools for AS00.00-Z- or jamming when working on damage and proper operation (visual inspection). 0001-01A loaded springs or spring bodies Wear protective gloves.

Replace self-locking nuts and bolts Installation

1 Raise vehicle.

AR32.20-P- 2 Tension rear spring (73) Installed state 0200-06MB

Tensioning device Fig 22

Tensioning plates Fig 23

Detach suspension strut (41) from *BA32.25-P- 3 spring link (72) 1005-04B

The rear spring can only be removed in Detach spring link (72) from wheel *BA35.20-P- 4 combination with the spring link. carrier 1002-01B Installation: The rear axle shaft must be horizontal when tightening the nut.

Detach spring link (72) from rear *BA35.20-P- 5 Installation: The rear axle shaft must be axle carrier 1001-01B horizontal when tightening the nut.

Remove spring link (72) together 6 Clean spring link in contact area with rear spring (73)

Relieve tension in rear spring (73) After replacing the rear spring or the rubber mount 7 and remove ↓

AP82.10-P- Check and correct headlamp adjustment 8260A

Insert rear spring (73) into spring AR32.20-P- 8 Removed state link (72) and tension 0200-06MB

9 Install in the reverse order

STRUTS Model Number Designation 220.025/026/028/063/065/067/070/073/074/075/125/126/128/163/165/167/170/173/174/175/176/178/179/875/878

Nut, rear BA32.25- spring P-1005- strut to Nm 110 04B spring link

SPRING LINK

Number Designation Model 220 with codes Z04, Z07

BA35.20-P-1001-01B Self-locking nut, track control arm to rear subframe Nm 120

BA35.20-P-1002-01B Self-locking nut, spring link to wheel carrier. Nm 120

Fig 29: Identifying Tensioning Device (202 589 01 31 00) Fig 30: Identifying Tensioning Plates (202 589 13 63 00)

Remove/Install Torsion/Stabilizer Bar On Front Axle - AR32.20-P-0300I

Remove/Install Stabilizer Bar On Front Axle - AR32.20-P-0300I

MODEL 220 (except 220.083 /084 /087 /183 /184 /187) except CODE (487) Active Body Control (ABC)

Fig 31: Identifying Stabilizer Bar On Front Axle Remove/Install Components

MODIFICATION NOTES

If the rubber boot of the stabilizer bar pivot bushing is damaged, the stabilizer bar pivot bushing 3rd 7.10.04 (and not the spring control arm) has to be replaced. stage

Remove/install

Risk of death caused by Align vehicle between the columns of the lifting platform and AS00.00-Z- vehicle slipping or toppling position the four support plates at the lifting platform support 0010-01A off of the lifting platform. points specified by the vehicle manufacturer.

Replace self-locking nuts AH00.00-N- and bolts. 0001-01A

Raise vehicle with lifting 1 platform

Remove bottom engine AR61.20-P- 2.1 Vehicles with gasoline engines compartment paneling 1105M 2.2 Remove bottom section of Vehicles with diesel engines AR94.30-P- soundproofing capsule 5300M

Check rubber boot of stabilizer bar pivot bushing in spring Unscrew nut (23c) and pry control arm (17) for damage and replace stabilizer bar pivot 3 link rod (23) off spring bushing if necessary: control arm (17). ↓

Fit new stabilizer bar pivot bushing. AR32.20-P- Installation: Press link rod (23) onto hexagon of stabilizer bar 0310M pivot bushing in spring control arm (17).

*BA32.20-P- 1001-02H

The threaded connection has been changed from M8 to M10. Unscrew bolts (21e) and When using new parts the nut M8 possibly fitted in the frame-type 4 remove retaining bracket integral support is to be replaced by a nut M10. Drill the hole in (21b) the frame-type integral support accordingly and protect against corrosion.

*BA32.20-P- 1003-02H

Check rubber mount on stabilizer bar (10) for damage and 5 Take off torsion bar (10) wear and replace stabilizer bar (10) if required. The rubber mounts are molded onto the torsion bar (10).

Installation: Tighten nut (23b) only when vehicle is in ready-to- Unscrew nut (23b) and drive condition. To do so, counterhold bolt (23d) with shortened 6 remove link rod (23) from Allen wrench (shop-made). Turn steering if necessary. torsion bar (10). Check rubber mount of link rod (23) for damage and replace link rod (23) if necessary.

*BA32.20-P- 1002-02H

7 Install in the reverse order

FRONT AXLE STABILIZER BAR

Number Designation Models 220 except 220.083/084/087/183/184/187

BA32.20-P-1001-02H Nut, link rod to spring control arm Nm 150

BA32.20-P-1002-02H Nut, link rod to stabilizer bar Nm 150

BA32.20-P-1003-02H Bolt, torsion bar to front end Nm 40

Detach/Install Link Rod At Torsion Bar - AR32.20-P-0300-02VB

FRONT AXLE TORSION STRUT

Number Designation Model 220.083/084/ 087/183/184/187

BA32.20-P-1002-02H Nut, link rod to torsion bar Nm 95

Removal

1. Remove self-locking nut (01) and bolt (02) from link rod (10) on torsion bar (11).

Check rubber mounts of link rod (10) for damage, install new link rod (10) if necessary.

Installation

2. Screw in self-locking nut (01) and bolt (02) of link rod (10) on torsion bar (11) .

Install new self-locking nut (01). Only tighten self-locking nut (01) when vehicle is ready to drive, turn steering if necessary. Fig 32: Identifying Self-Locking Nut, Link Rod And Bolt

Remove/Install Torsion Bar On Front Axle - AR32.20-P-0300IW

MODELS 220.083 /084 /087 /183 /184 /187

Fig 33: Identifying Torsion Bar On Front Axle Remove/Install Components

Remove/Install

Align vehicle between the columns of the lifting Risk of death cased by vehicle slipping or platform and position the four support plates at the AS00.00-Z- toppling off of the lifting platform. lifting platform support points specified by the 0010-01A vehicle manufacturer.

AH00.00-N- Notes on self-locking nuts and bolts 0001-01A

1 Raise vehicle.

Detach lower engine compartment AR61.20-P- 2 paneling 1105M

Check rubber mount of link rod (23) for damage and replace link rod (23) if necessary. 3 Detach link rod (23) from torsion bar (10) Installation: Only tighten the nut (23b) when the vehicle is in the curb condition and turn the steering onto lock if necessary.

*BA32.20-P- Nut, link rod to torsion bar (10) 1002-02H

4 Detach torsion bar (10) on the left and right Check rubber mount of torsion bar (10) for of the retaining brackets (21b) from the damage and wear and replace torsion bar (10) if front axle carrier and remove torsion bar necessary. (10) The rubber mounts are molded onto the torsion bar (10).

*BA32.20-P- Bolts (21e) of torsion bar to front axle carrier 1003-02H

Detach retaining brackets (21b) from 5.1 If necessary torsion bar (10)

Bolts (21g) bottom retaining bracket to top *BA32.20-P- retaining bracket 1005-02H

Check boot of link rod (23) for damage and replace link rod (23) if necessary. Detach link rod (23) from steering knuckle 6 Installation: Counterhold joint of link rod (23) (5) when tightening so that the boot is not twisted or damaged.

*BA32.20-P- Nut, link rod to steering knuckle 1004-02H

7 Install in the reverse order

FRONT AXLE TORSION STRUT

Model Number Designation 220.083/084/087/183/184/187

BA32.20-P-1002- Nut, link rod to torsion bar Nm 95 02H

BA32.20-P-1003- Bolt, torsion bar to front end Nm 40 02H

BA32.20-P-1004- Nut, link rod to steering knuckle Nm 95 02H

BA32.20-P-1005- Bolt, bottom retaining bracket to top retaining Nm 95 02H bracket

Remove/Install Torsion Bar On Front Axle - AR32.20-P-0300MB

MODEL 220.175 /178 with CODE (Z07) Top protection

Fig 34: Identifying Torsion Bar On Front Axle Remove/Install Components

Remove/Install

Replace self-locking nuts and bolts Installation

Remove front pipe of fire Only applies to vehicles with fire extinguishing 1 extinguishing system system.

Installation: Press link rod (23) onto the Unscrew nut (23c) and detach link hexagon of the ball joint in the spring link (17) 2 rod (23) from spring link (17). Inspect ball joint in spring link (17) for damage, replace ball joint if necessary.

*BA32.20-P- 1001-02H

Unscrew bolts (21e) and remove *BA32.20-P- 3 retaining bracket (21b). 1003-02H

4 Take off torsion bar (10) The rubber mounts are molded onto the torsion bar. If they are damaged or worn, replace the torsion bar.

Installation: Only tighten nut (23b) when vehicle is in ready to drive condition. Counterhold bolt (23d) with shortened Allen Unscrew nut (23b) and remove link 5 wrench shop-made for this step. Knock in wheel if rod (23) from torsion bar (10). necessary. Check rubber mount of link rod (23) for damage, replace link rod if necessary.

*BA32.20-P- 1002-02H

6 Install in the reverse order

FRONT AXLE TORSION STRUT

Number Designation Model 220 except 220.083/084/087/183/184/187

BA32.20-P-1001-02H Nut, linkage rod to track control arm Nm 150

BA32.20-P-1002-02H Nut, link rod to torsion bar Nm 150

BA32.20-P-1003-02H Bolt, torsion bar to front axle carrier Nm 40

Install New Stabilizer Bar Pivot Bushing - AR32.20-P-0310M

MODEL 211 (except 211.08 /09 /28 /29) in the spring control arm

MODEL 220 (except 220.08 /18) except CODE (487) Active Body Control (ABC) in spring control arm

MODEL 230 except CODE (487) Active Body Control (ABC) in spring control arm

Illustrated on model 220

Fig 35: Installing Stabilizer Bar Pivot Bushing (Model 220)

Remove/install

Align vehicle between columns of Risk of death caused by vehicle slipping or vehicle lift and position four support AS00.00-Z- toppling off of the lifting platform. plates at vehicle lift support points 0010-01A specified by vehicle manufacturer.

AH00.00-N- Notes on self-locking nuts and bolts 0001-01A

When working on the front-end assembly, be careful not to scratch, mark or notch the surfaces of aluminum parts. Otherwise the service life of the parts will be affected

Tighten nuts and bolts of chassis components Installation only when vehicle is in ready-to-drive condition

1 Remove front wheel

AP40.10-P- Remove/install wheels 4050Z

Detach torque strut (18) from steering knuckle AR33.15-P- 2 Model 220 except 220.8, 230 (5) 0160-01I

Type 220.8 AR33.15-P- Installation: Replace self-locking nut. 0160-01MB Check rubber boot on ball head of torque strut (18) for damage. If rubber boot is damaged, install new torque strut (18): ↓ Remove/install torque strut:

AR33.15-P- Model 220 except 220.8 0160I

AR33.15-P- Type 220.8 0160MP

AR33.15-P- Model 230 0160R

Remove track rod (10) from steering knuckle AR46.40-P- 3 Installation: Replace self-locking nut. (5). 0200-02I

To do so, counterhold bolt (23d) with shortened Allen wrench (shop-made). Turn steering if necessary. 4 Undo nut (23b) Installation: Tighten nut (23b) only when vehicle is in ready-to-drive condition.

*BA32.20-P- Model 211 1002-02B

*BA32.20-P- Model 220, 230 1002-02H

Unscrew nut (23c), Installation: Press link rod (23) onto 6 detach link rod (23) from spring control arm hexagon of stabilizer bar pivot bushing (17) and swing vertically upward (8) on spring control arm (17).

On model 211 up to chassis number AR32.35-P- 1A 762000, in addition both link rods 3328T (23) must be replaced.

*BA32.20-P- Model 211 1006-02B

*BA32.20-P- Model 220, 230 1001-02H

When pressing out the ball joint with Remove rubber boot (9) and wire fasteners of rubber boot assembled the special tool 7 torsion bar pivot bushing (8) will be damaged due to the press-out force which is too high.

Press stabilizer bar pivot bushing (8) out of AR32.20-P- 8 spring control arm (17) 0310-01M

Checking

Model 220 except 220.8, 230 If rubber boot (19) is damaged, install Check rubber boot (19) of ball joint in spring 9 new spring control arm (17): ↓ control arm (17) for damage Remove/install, spring control arm at front axle:

AR33.15-P- Model 220 except 220.8 0170I

AR33.15-P- Type 220.8 0170MP

AR33.15-P- Model 230 0170R

Model 220 except 220.8, 230 Replace rubber mount if necessary: Check rubber mount of spring control arm (17) 10 ↓ for damage Replace rubber mount of spring control arm:

Model 220 except 220.8, 230 AR33.15-P- Type 220.8 0170-02I

11 Install in the reverse order

FRONT AXLE STABILIZER BAR

Model 211 except model Number Designation 211.08/09/28/29

BA32.20-P-1002- Self-locking nut of connecting rod to M14x1.5 Nm 130 02B torsion bar

BA32.20-P-1006- Self-locking nut, link rod to joint piece Nm 130 02B FRONT AXLE STABILIZER BAR

Model 220 except Model Number Designation 220.083/084/087/183/184/187 230

BA32.20-P-1001- Nut, link rod to spring control Nm 150 110 02H arm

BA32.20-P-1002- Nut, link rod to stabilizer bar Nm 150 110 02H

Press Out/Press In Stabilizer Bar Pivot Bushing - AR32.20-P-0310-01M

Fig 36: Identifying Press Out/In Tool (220 589 07 43 00)

Fig 37: Identifying Press (163 589 03 43 00) Fig 38: Pressing Out/In Stabilizer Bar Pivot Bushing (Shown On Model 220)

Shown on model 220

Press out

Do not use an impact wrench or other compressed-air tool otherwise the threaded spindle on the puller (2) will be damaged.

The threaded spindle on puller (2) is only used for retensioning and not for pressing out the stabilizer bar pivot bushing (8).

It is essential to remove the rubber boot (and its wire fasteners) of the torsion bar pivot bushing (8), otherwise the puller (2) will be damaged as a result of the high press-out forces.

1. Press out stabilizer bar pivot bushing (8) with puller (2), press (1), press-out sleeve (2.1) and counterholder (2.3) from the spring control arm (17) opposite to the direction of travel.

Attach the counterholder (2.3) correctly on the stabilizer bar pivot bushing (8) (see picture). The bore in the counterholder (2.3) must be seated centrally over the stabilizer bar pivot bushing (8).

The removal and installation tool 220 589 07 43 00 contains:

1. Puller (2)

2. Press-out sleeve (2.1)

3. Counterholder (2.3) Fig 39: Pressing Out Stabilizer Bar Pivot Bushing (Shown On Model 220)

Shown on model 220

Pressing in

2. Clean mounting hole in the spring control arm (17).

3. Using puller (2), press (1), press-in sleeve (2.2) and counterholder (2.3) press stabilizer bar pivot bushing (8) into spring control arm (17) in the direction of travel.

The removal and installation tool 220 589 07 43 00 contains:

1. Puller (2)

2. Press-in sleeve (2.2)

3. Counterholder (2.3)

Remove/Install Stabilizer Bar On Rear Axle - AR32.20-P-0315 Remove/Install Stabilizer Bar On Rear Axle - AR32.20-P-0315I

MODEL 220 except CODE (487) Active Body Control (ABC)

Fig 40: Identifying Stabilizer Bar On Rear Axle Remove/Install Components

Fig 41: Identifying Rear Torsion Bar, Link Rod And Nut

MODIFICATION NOTES

Value changed from 95 Nm to: 1st stage Value changed to BA35.10-P-1001-01A for *BA35.10-P-1001- 6.9.00 60 Nm model 220 01A 2nd stage 90°

Remove/install

Align vehicle between the four pillars of the hoist Risk of death caused by vehicle and position the four support plates at the hoist AS00.00-Z- slipping or toppling off of the lifting mounting points specified by the vehicle 0010-01A platform. manufacturer.

Replace self-locking nuts and bolts

1 Remove rear wheels

AP40.10-P- 4050Z

Remove exhaust system as of flange 2 See: ↓ connection

AR49.10-P- Remove complete exhaust system 7000AA

Unhook brake cables from automatic 3 See: ↓ slack adjuster of parking brake

AR42.20-P- Remove rear brake cable 0525I

Unscrew bolts of propeller shaft *BA41.40-P- 4 intermediate bearing. 1001-01A

Remove propeller shaft from rear axle AR41.10-P- 5 The Hardy coupling remains with the driveshaft. center assembly. 0050-04I

*BA41.10-P- 1002-01A

6 Release fitting sleeves on flex disks Tie up propeller shaft to one side. AR41.10-P- 0050-09I Drift for releasing the fitting sleeves in WF58.50-P- the flexible couplings 4110-01A

Unscrew nut (81e) for level sensor *BA82.10-P- 7 control rod (85) from torsion bar link 1001-02A (81) of torsion bar (77)

Remove nuts (78b/78c) holding link rod *BA32.20-P- 8 (78) between torsion bar (77) and wheel 1001-04G carrier.

*BA32.20-P- 1002-04G

Unscrew bolts (72d) on spring control 9 arm cover (72c).

Remove the bolted connection *BA32.25-P- 10 (41b/41c) of the suspension strut (41) 1005-04B on the spring link (72)

Undo bolted connection (77e/77f) *BA32.20-P- 11 between torsion bar (77) and rear-axle 1003-04G carrier

Use assembly attachment, pit hoist or 12 Fig 42 floor jack to support final-drive unit.

Remove front rear axle suspension 13 Installation: recut thread on frame floor with tap bolts (71a)

*BA35.10-P- 1001-01A

When lowering the rear axle use caution to Carefully lower the rear axle until the 14 ensure that no electrical wiring, cables or brake torsion bar (77) is free. lines are damaged.

The rubber mounts are molded onto the torsion Remove torsion bar (77) towards the 15 bar (77). If they are damaged or worn, replace the side torsion bar (77).

Unscrew nuts (81b) from torsion bar link Installation: The flat on the torsion bar 16 (81) and remove retaining bracket (81a) intermediate lever (81) must align with the flat on with torsion bar link (81) the torsion bar (77)

*BA32.20-P- 1004-04G

17 Install in the reverse order

REAR AXLE STABILIZER BAR

Number Designation Model 220

BA32.20-P-1001-04G Nut, link rod to wheel carrier Nm 40

BA32.20-P-1002-04G Nut, link rod to stabilizer bar Nm 40

BA32.20-P-1003-04G Bolt, torsion bar to rear subframe Nm 70

BA32.20-P-1004-04G Nut, torsion bar link to retaining bracket Nm 3

PROPELLER SHAFT INTERMEDIATE BEARING

Model Number Designation 220

Bolt with washer Nm -

Bolt with collar and self- BA41.40-P-1001- Bolt, propeller shaft intermediate bearing to Nm 30 centering tip 01A frame floor assembly Bolt with collar and without self- Nm - centering tip

DRIVESHAFT

Model Number Designation 220

BA41.10-P-1002- Self-locking nut, flexible coupling to rear propeller shaft or rear axle M10 Nm - 01A differential. M12 Nm 60

REAR AXLE CARRIER

Number Designation Model 220

Nm -

Stage with bolt Nm 60 1

flange ø 24 Stage BA35.10-P-1001- Self-locking bolt, front rear axle carrier rubber mount to ∠° 90 mm 2 01A frame floor Stage with bolt Nm 60 1

Flange ø Stage ∠° 90 26mm 2

STRUTS

Models Number Designation 220.025/026/028/063/065/067/070/073/074/075/125/126/128/163/165/167/170/173/174/175/176/178/179/875/878

Nut, rear BA32.25- strut to P-1005- spring Nm 110 04B control arm

REAR AXLE LEVEL SENSOR

Model 220 except model 220 with code Number Designation 487

BA82.10-P-1001- Nut, lever sensor control rod to torsion bar Nm 10 02A link

Fig 42: Identifying Assembly Attachment (140 589 01 62 00)

Remove/Install Stabilizer Bar On Rear Axle - AR32.20-P-0315MB

MODEL 220.175 /178 with CODE (Z07) Top protection Fig 43: Identifying Stabilizer Bar On Rear Axle Remove/Install Components

Remove/install

Align vehicle between the four pillars of the hoist Risk of death caused by vehicle and position the four support plates at the hoist AS00.00-Z- slipping or toppling off of the lifting mounting points specified by the vehicle 0010-01A platform. manufacturer.

Replace self-locking nuts and bolts Installation

1 Remove rear wheels.

Position lifting platform pillar support plates on the lifting support strongpoints specified by the automotive manufacturer so that the armor plates on the underfloor can be removed.

AP40.10-P- 4050Z

Remove exhaust system as of 2 flange connection

AR49.10-P- Remove complete exhaust system 7000AA

AR61.40-P- 3 Remove underside guard 1000MB

Unhook brake cables from 4 automatic slack adjuster of parking brake

AR42.20-P- Remove rear brake cable 0525I

Unscrew bolts of propeller shaft *BA41.40-P- 5 intermediate bearing. 1001-01A

Remove propeller shaft from rear The flexible coupling remains installed on the AR41.10-P- 6 axle center assembly. propeller shaft. 0050-04I

*BA41.10-P- 1002-01A

Loosen fitting sleeves on flexible AR41.10-P- 7 Tie up propeller shaft to one side. couplings. 0050-09I

Drift for loosening fitting sleeves in WF58.50-P- flex disks. 4110-01A

Unscrew nut (81e) for level sensor *BA82.10-P- 8 control rod (85) from torsion bar link 1001-02A (81) of torsion bar (77)

Remove nuts (78b/78c) holding link *BA32.20-P- 9 rod (78) between torsion bar (77) 1001-04G and wheel carrier.

*BA32.20-P- 1002-04G

Remove track control arm shield 10 (72c). Risk of injury caused by pinching Use only approved tensioning devices; shield off AS00.00-Z- or crushing when working on hazard area if necessary. 0001-01A springs or spring bodies that are Inspect special tools for damage and proper under load operation (visual inspection). Wear protective gloves.

AR32.20-P- 11 Tension rear springs (73). 0200-06MB

Tensioning device Fig 22

Tensioning plates Fig 23

Remove suspension strut (41) from *BA32.25-P- 12 spring control arm (72). 1005-04B

Undo bolted connection (77e/77f) *BA32.20-P- 13 between torsion bar (77) and rear- 1003-04G axle carrier

Use a suitable assembly attachment 14 and inspection pit lift or assembly lift to support rear axle.

Installation: recut thread on frame floor with Unscrew bolts (71a) of front rear- tap. 15 axle mount. Ensure that the stop plate (arrow) for the front rear axle mount is correctly positioned.

*BA35.10-P- 1001-01A

When lowering the rear axle use caution to Carefully lower rear axle until the 16 ensure that no electrical wiring, cables or brake torsion bar (77) is free. lines are damaged.

The rubber mounts are molded onto the torsion Remove torsion bar (77) towards the 17 bar (77). If they are damaged or worn, replace the side torsion bar (77).

Unscrew nuts (81b) from torsion bar Installation: The flat on the torsion bar link (81) and remove retaining 18 intermediate lever (81) must align with the flat on bracket (81a) with torsion bar link the torsion bar (77) (81)

*BA32.20-P- 1004-04G

19 Install in the reverse order

REAR AXLE STABILIZER BAR

Number Designation Model 220

BA32.20-P-1001-04G Nut, link rod to wheel carrier Nm 40

BA32.20-P-1002-04G Nut, link rod to stabilizer bar Nm 40

BA32.20-P-1003-04G Bolt, torsion bar to rear subframe Nm 70

BA32.20-P-1004-04G Nut, torsion bar link to retaining bracket Nm 3

PROPELLER SHAFT INTERMEDIATE BEARING

Model Number Designation 220

Bolt with washer Nm -

Bolt with collar and self- BA41.40-P-1001- Bolt, propeller shaft intermediate bearing to Nm 30 centering tip 01A frame floor assembly Bolt with collar and without self- Nm - centering tip

DRIVESHAFT

Model Number Designation 220

BA41.10-P-1002- Self-locking nut, flexible coupling to rear propeller shaft or rear axle M10 Nm - 01A differential. M12 Nm 60

REAR AXLE CARRIER

Model Number Designation 220 Nm -

Stage with bolt Nm 60 1

flange ø 24 Stage BA35.10-P-1001- Self-locking bolt, front rear axle carrier rubber mount to ∠° 90 mm 2 01A frame floor Stage with bolt Nm 60 1

Flange ø Stage ∠° 90 26mm 2

STRUTS

Models Number Designation 220.025/026/028/063/065/067/070/073/074/075/125/126/128/163/165/167/170/173/174/175/176/178/179/875/878

Nut, rear BA32.25- strut to P-1005- spring Nm 110 04B control arm

REAR AXLE LEVEL SENSOR

Model 220 except model 220 with code Number Designation 487

BA82.10-P-1001- Nut, lever sensor control rod to torsion bar Nm 10 02A link

Fig 44: Identifying Tensioning Device (202 589 01 31 00) Fig 45: Identifying Tensioning Plates (202 589 13 63 00)

Seal Top Air Suspension Strut - AR32.22-P-1600I

MODEL 220 except CODE (487) Active Body Control (ABC)

Shown on right air suspension strut

Fig 46: Identifying Pressure Line Connection, Residual Pressure Retaining Valve And Circlip

Fig 47: Sealing Top Air Suspension Strut (1 Of 2) Fig 48: Sealing Top Air Suspension Strut (2 Of 2)

Fig 49: Identifying Air Spring Plunger And Support Bushing

Removing

Risk of death caused by vehicle Align vehicle between columns of vehicle lift and AS00.00-Z- slipping or toppling off of the lifting position four support plates at vehicle lift support points 0010-01A platform. specified by vehicle manufacturer.

AH00.00-N- Notes on self-locking nuts and bolts 0001-01A

Open engine hood and raise to AR88.40-P- 1 vertical position 1000M

Raise vehicle to the extent that work can still be 2 Raise vehicle carried out in the engine compartment.

Discharge air suspension struts using 3 STAR DIAGNOSIS diagnosis system STAR DIAGNOSIS

AH32.22-P- Notes on AIRmatic 1000-02I

Unscrew pressure line connection (1) 4 and place pressure line to the side

When dissolving the casting compound, flying 5 Cover engine compartment around parts can enter into the openings of the engine.

Risk of injury to skin and eyes Wear safety gloves, protective clothing and safety AS00.00-Z- caused by handling hot or glowing glasses, if necessary. 0002-01A objects.

Heat adhesive until it softens. At the same time Warm up casting compound with 6 check the hardness with a screwdriver. hot air blower Hot air blower

Separate casting compound with Always remove separated parts of the casting 7 screwdriver compound with vacuum cleaner.

Close the opening of the residual pressure retaining Unscrew residual pressure retaining 8 valve (2) with a bolt M8 (6), so that no dirt can penetrate valve (2) with adapter into the air suspension strut.

Adapter Fig 51

Always remove remaining casting 9 There must be no burrs and dirt particles. compound with screwdriver

Only one nut (5) must always be undone and Screw in the bolts (010a) of the replaced by a bolt (010a) of the removal and removal and extraction tool (010) in installation tool (010). When releasing several nuts (5), 10 stages corresponding to the sequence the air suspension strut can slip out toward bottom and of pictures and secure with cotter pins can be damaged. Installation: Install new nuts. (5).

Removal/installation tool Fig 50

Press down cover (4) with the 11 removal and installation tool (010), until the circlip (3) is loose

12 Use a screwdriver to remove the circlip (3) Make sure it does not cause any scratches and burrs, otherwise the sealing ring of the new cover (4) is damaged when installing.

Release removal and installation Check surfaces at air suspension strut and the 13 tool (010) and remove cover (4) with groove of the circlip (3) for sharp edges. Remove sharp bar magnet edges if required.

Install

Apply grease paste onto the sealing ring of the new cover (4) 14 Insert new cover (4) Do not use any oils and grease (mineral oil products), these can damage the sealing ring and lead to leakage of the air suspension strut.

When pressing in, ensure that the new cover (4) is Press in cover (4) with removal and pressed in evenly and is not tilted. Otherwise the 15 installation tool (010) sealing ring of the cover (4) is damaged and this leads to the leakage of the air suspension strut.

16 Fit circlip (3) Install new circlip (3).

Fit on nuts (5) by hand and after filling the air Unscrew cotter pins of the bolts suspension strut tighten in curb condition. (010a) of the removal and Only one bolt (010a) of the removal and 17 installation tool (010) and remove bolt installation tool (010) must be undone and replaced by (010a) in the reverse installation a nut (5). When several bolts (010a) are undone the air sequence suspension strut can slip downwards and be damaged.

*BA32.25- Model 220 except 220.875 P-1001-04B

*BA32.25- Model 220.875 P-1001-04C

Glue upper center console of air 18 suspension strut in the engine The surfaces must be free of grease before painting. compartment

Risk of explosion caused by paint No smoking! No open flames! Use respiratory AS98.00-Z- vapors igniting. Risk of poisoning protection, protective clothing, gloves, safety goggles 0002-01A caused by inhaling paint vapors. and skin cream. Ensure that the area is well ventilated.

Coat damaged surfaces at air 19 suspension top section with primer Let painted surfaces dry. filler and paint with black acrylic paint

AH98.00-P- Notes on paintwork repairs 9408-02A

Unscrew bolt M8 (6) from the opening of the residual pressure retaining Attach residual pressure retaining valve (2) by hand 20 valve (2) and screw in new residual and tighten with adapter . pressure retaining valve (2) with adapter

Adapter Fig 51

*BA32.25- Model 220 except 220.875 P-1013-04B

*BA32.25- Model 220.875 P-1007-04C

Check O-ring of pressure line for damage and 21 Screw on pressure line connection (1) replace if required.

*BA32.25- Model 220 except 220.875 P-1003-04B

*BA32.25- Model 220.875 P-1002-04C

Raise the vehicle until there is good access to the 22 Lift vehicle further bellows (7) of the air suspension strut.

When working on the air suspension strut, Align bellows (7), for this step press unintended wrinkle formations at the bellows (7) can 23 the bellows (7) toward top and pull in occur. The wrinkle formations must be eliminated, released position toward bottom. otherwise this can lead later to a failure of the air suspension.

24 Pressurize air suspension strut using The wheels must not be in contact with the ground STAR DIAGNOSIS during the filling. When filling in deflected condition, the air suspension bellows is destroyed inside the air suspension strut. When filling the air spring plunger (8) must be pulled downwards and pressed onto the support bearing (9). No air must escape at the contact surface (arrow) otherwise no pressure can be built up in the air suspension strut. STAR DIAGNOSIS diagnosis system Check top air suspension strut for Spray repaired point with soap water. Pay attention AR32.22-P- 25 leaks to bubble formation during the rocking at front end. 8100I

STRUTS

Model Models Number Designation 220.025/026/028/063/065/067/070/073/074/075/125/126/128/163/165/167/170/173/174/175/176/178/179/ 220.083/084/087/183/184/187

Nut connecting BA32.25- front P-1001- Nm 20 20 suspension 04B strut to front end

Air suspension BA32.25- pressure P-1003- Nm 5 5 line to front 04B suspension strut

Residual pressure BA32.25- retaining P-1013- valve to Nm 12 12 04B front suspension strut

STRUTS

Number Designation Model 220.875/878

BA32.25-P-1001-04C Nut connecting front suspension strut to front end Nm 20

BA32.25-P-1002-04C Air suspension pressure line to front suspension strut Nm 5

BA32.25-P-1007-04C Residual pressure retaining valve to front suspension strut Nm 12

Fig 50: Identifying Removal, Installation (220 589 00 61 00) Fig 51: Identifying Adapter (220 589 00 09 00)

Remove Compressor, Install - AR32.22-P-2001I

MODEL 220 except CODE (487) Active Body Control (ABC)

Fig 52: Identifying Pressure Line Connection, Intake Hose With Air Filter And AIRmatic Compressor Unit

Fig 53: Identifying Air Compressor Relay

Remove/install

AH32.22-P- Special information on AIRmatic 1000-02I Risk of explosion caused by No fire, sparks, open flames or smoking. Wear AS54.10-Z- oxyhydrogen gas. Risk of poisoning and acid-resistant gloves, clothing and safety glasses. 0001-01A caustic burns caused by swallowing Pour battery acid only into suitable and battery acid. appropriately marked containers. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

AH54.10-P- Notes on battery All models 0001-01A

AR54.10-P- 1 Disconnect battery 0003I

AR61.20-P- 2 Remove engine compartment paneling Right front part only 1105M

Plug the pressure line for the duration of the Unscrew pressure line connection (1) *BA32.22-P- 3 repair operations. from AIRmatic compressor unit (A9/1) 1004-03A If pressure line or its connection fittings are damaged:↓

AR32.22-P- Repair AIRmatic pressure line connection 2001-02I

Detach connector on AIRmatic pressure 4 reduction valve (A9/1y1)

Disconnect connector for air compressor 5 motor (3)

Installation: If the air filter (2) is replaced, the Pull intake hose with air filter (2) out of 6 arrow on the air filter (2) must point towards the longitudinal member longitudinal member.

Unscrew nuts (arrows) and remove *BA32.22-P- 7 AIRmatic compressor unit (A9/1) 1003-03A

Only when installing a new air compressor. When replacing the air compressor the air 8.1 Detach air compressor relay (K40/7kO) compressor relay (K40/7kO) should always be exchanged as the switching contacts may be predamaged.

9 Install in the reverse order

AR32.22-P- 10 Check AIRmatic for leaks. 8100I

AIR SUSPENSION

Number Designation Model 220

M5 Nm 3 BA32.22-P-1003-03A Nut, compressor to bracket M6 Nm -

BA32.22-P-1004-03A Pressure line, air suspension to compressor Nm 5

Repairing AIRmatic Pressure Line Connection - AR32.22-P-2001-02I

MODIFICATION NOTES

Value changed from 5 Nm to 2 Figure revised to BA32.25-P-1003-04B on model 211 *BA32.25-P-1003- 9.7.02 Nm Airmatic 04B

Value changed from 5 Nm to 2 Value changed in BA32.25-P-1006-04B for model 211 *BA32.25-P-1006- 9.7.02 Nm Airmatic 04B

STRUTS

Model Models Models Number Designation 211 220.025/026/028/063/065/067/070/073/074/075/125/126/128/163/165/167/170/173/174/175/176/178/179/ 220.083/084/087/183/184/187 Airmatic

Air suspension BA32.25- pressure P-1003- Nm 2 5 5 line to front 04B suspension strut

Air BA32.25- suspension P-1006- pressure Nm 2 5 5 04B line to rear air spring STRUTS

Model 220 with code Model Number Designation Z07 220.875/878

BA32.25-P-1002- Air suspension pressure line to front Nm 5 5 04C suspension strut

BA32.25-P-1005- Pressure line, air suspension to rear strut Nm 5 5 04C

Fig 54: Identifying Hose Cutter (000 589 12 28 00)

Fig 55: Identifying Wrench Socket (211 589 00 09 00)

REPAIR MATERIALS Number Designation Order number

Christof Fischer GmbH, Augsburger Str. 289-293, 70327 Stuttgart BR00.45-Z-1002-03A Leak detection spray Germany Tel. +49 711 30502-0 Fax +49 711 30502-10 www.kaeltefischer.de

In the event of damage to compressed-air terminals (1a) and pressure lines (4) a compressed-air connector (3) or a repair screwed connection (1) can be mounted.

Ensure that the repair is carried out carefully in order to avoid further leaks.

1. Undo compressed-air terminal (1a) from affected component (e.g. suspension strut) and cut pressure line (4) to suitable length using the knife.

Special care must be taken to ensure that the cut is exactly at right angles to the pressure line (4).

2. Insert the truncated pressure line (4) up to the stop or 19.5 mm into the pressure line connector (3). Fig 56: Identifying Pressure Line, Pressure Line Connector And Compressed-Air Terminal

3. Cut the repair line (2) so as to obtain the original length and shape (straight end or 90° arc) of the line.

Do not kink repair line (2). When cutting off the repair line (2) take int account the insertion depths in the repair screwed connection (1) and pressure line connector (3).

Repair lines (2) supplied from through the spare parts channels, each repair (2), with one straight and one bent end.

4. Insert the repair line (2) up to the stop or to a depth of 19.5 mm in the pressure line connector (3).

5. Screw the repair bolted connection (1) into the component in question.

6. Pull plastic guard (1c) out of repair connection (1).

7. Insert the repair line (2) into the repair bolted connection (1) up to the stop or to a depth of 19.5 mm.

If necessary mark the repair line (2) at 19.5 mm with a felt-tip pen beforehand.

After insertion the pull back the pressure line (4) slightly so that the circumferential retaining edges inside the clamping ring (1b) engage in the outer surface of the line.

When pulling in or routing the pressure line (4) make sure that the pressure line (4) cannot be twisted once fastened. The pressure line connectors (3) should be attached with cable ties at a suitable point on the vehicle so that chafing of the pressure line (4) or noise are prevented If bubbles form at the repair point after a leak test with leak detector spray, it must be checked whether the pressure line (4) is inserted as far as the stop. If bubbles continue to form nevertheless, then the pressure line connector (3) may be defective and a new pressure line connector (3) or a new repair bolted connection (1) should be used.

Removing And Installing AIRmatic Central Reservoir - AR32.22-P-2017I

MODEL 220 except CODE (487) Active Body Control (ABC)

Fig 57: Identifying Central Reservoir, Pressure Line Connection And Screw

Remove/install

AH32.22-P- Special information on AIRmatic 1000-02I

Drain AIRmatic system using Star 1 Do not deflate the suspension struts. Diagnosis

2 Undo bolt (arrow) on bumper

3 Remove lamp unit

Remove engine compartment AR61.20-P- 4 Left front part only paneling 1105M

Unscrew pressure line terminal Seal off the pressure line with a blind plug for the duration *BA32.22-P- 5 (42a) on central reservoir (42) of the repair work If pressure line or its connection fittings 1002-03A are damaged:↓

AR32.22-P- Repairing AIRmatic pressure line connection 2001-02I

Unscrew bolts (42b) and remove *BA32.22-P- 6 central reservoir (42) 1001-03A

7 Install in the reverse order

Fill AIRmatic system using Star 8 Diagnosis

AR32.22-P- 9 Check AIRmatic for leaks. 8100I

AIR SUSPENSION

Number Designation Model 220

BA32.22-P-1001-03A Bolt of central reservoir to bracket Nm 8

BA32.22-P-1002-03A Pressure line of air suspension to central reservoir Nm 5

Remove/Install Air Suspension Control Unit - AR32.22-P-6000I

MODEL 220 except CODE (487a) Active body control (ABC) Fig 58: Identifying Locking Slide, Data Bus System Connector, Left Fuse Box And AIRmatic With ADS Control Unit

Remove/Install

AR54.10-P- 1 Connect no load current retention unit 1030-07I

AR54.10-P- 2 Disconnect ground cable of battery 0003I

AR88.40-P- 3 Open engine hood and position upright 1000M

4 Unlock and remove cover of left fuse box (F1)

Pull out locking slide (1a) of the two couplings (1) on the AIRmatic The locking slides are 5 with ADS control unit (N51) in direction of arrow as far as the stop located below the line entries and remove connections.

Disconnect connector of data bus system (2) from AIRmatic with 6 ADS control unit

When replacing the control Remove AIRmatic with ADS control unit upwards out of left fuse 7 unit calibrate it using STAR box diagnosis

8 Install in the reverse order

Inspecting AIRmatic For Leaks - AR32.22-P-8100I

MODEL 220 except CODE (487a) Active body control (ABC)

Fig 59: Identifying Pressure Line Connections

Checking

AH32.22- Notes on AIRmatic P-1000-02I 1 Remove engine compartment lining Only on the right-hand side of the AR61.20- vehicle for testing the AIRmatic P-1105M compressor unit (A9/1)

Only on the right-hand side of the 2 Remove part of the wheel house inner panel in front fender vehicle for testing the level control valve unit (Y36/6)

Wait for approx. 10-15 minutes after Spray the pressure line connections (1VL, 2VR, 3HL, 4HR, spraying. This means that minor leaks 5SP,P) of the level control valve unit (Y36/6), the pressure can be recognized (forming a white 3 line connection of the AIRmatic compressor unit (A9/1) and cap). Severe leaks are evident the pressure line connection (42a) of the central reservoir immediately. (42) with leak detecting spray Use leak detecting spray

Wait for approx. 10-15 minutes after Spray the area of the casting compound and pressure line spraying. This means that minor leaks 4 connections (40a, 41a) on the spring struts (40, 41) with can be recognized (forming a foam leak detecting spray crown). Severe leaks are evident immediately.

4 Use leak detecting spray

Remove/Install Rear Suspension Strut - AR32.25-P-1016

Remove/Install Rear Suspension Strut - AR32.25-P-1016I

MODEL 220 except CODE (487) Active Body Control (ABC)

Fig 60: Identifying Rear Suspension Strut Remove/Install Components

Fig 61: Identifying Threaded Connection, Thrust Arm And Spring Control Arm

MODIFICATION NOTES

25.4.03 Loosen spring control arm on rear axle carrier, step revised Step 9

25.4.03 Loosen thrust arm on rear axle carrier, newly incorporated Step 10

Remove/Install

Align vehicle between the columns of the lifting AS00.00-Z- platform and position the four support plates at the 0010-01A Risk of death cased by vehicle lifting platform support points specified by the vehicle slipping or toppling off of the lifting manufacturer. platform.

AH00.00-N- Replace self-locking nuts and bolts 0001-01A

AH32.22-P- Special information on AIRmatic Model 220 1000-02I

Discharge suspension struts 1 concerned (41) using STAR DIAGNOSIS

Connect STAR DIAGNOSIS and AD00.00-P- read out fault memory 2000-04A

2 Remove rear wheels

Remove/install wheels, rotate if AP40.10-P- necessary 4050Z

3 Remove cover (arrow) in rear shelf

Unscrew pressure line connection *BA32.25-P- 4 (41a). 1006-04B

Residual pressure in suspension strut up to 3.5 bar. If residual pressure valve is damaged, install new suspension strut (41). Seal off pressure line with blind plugs during repair work. If pressure line connections or pressure lines are damaged: ↓

AR32.22-P- Repair AIRmatic pressure line connection. 2001-02I

Installation: Fit nuts (41b) then refill suspension 5 Unscrew nuts (41b). strut in fully-assembled vehicle before torquing to specification.

Installation: To facilitate tightening operations and AR68.30-P- ensure the correct torque on the nuts (41b), it may 4490M prove useful to remove the trim from the C-pillar.

*BA32.25-P- 1004-04B

Pull off grommet and disconnect 6 electrical connector of damping valve unit (Y53x1/Y54x1).

Unscrew bolts (72d) on spring control 7 arm cover (72c).

Remove threaded connection (2) of Installation: Fit nuts (41b) and tighten after filling 8 suspension strut (41) on spring the suspension strut on a vehicle which is ready to control arm (72). drive.

*BA32.25-P- 1005-04B

Remove threaded connection (1) of *BA35.20-P- 9 spring control arm (72) on rear axle 1001-01A carrier.

Remove threaded connection (3) of 10 Model 220 except model 220.874/875/878 thrust arm (4) on rear axle carrier.

*BA35.20-P- Model 220.874/875/878 1001-05A

*BA35.20-P- 1001-05B

Pull down spring control arm (72) and remove suspension strut (41) by AR32.25-P- 11 Do not damage brake hose. lowering it and pulling it out to the 1017-02I side.

*BA32.25-P- 1004-04B

If replacing or reinstalling the suspension struts (41), check condition of suspension struts and if necessary: ↓

OS32.25-P- Dispose of suspension strut 0122-01J

12 Install in the reverse order

13 Fill suspension struts affected using Pressurize to 5 bar. STAR DIAGNOSIS During filling, the wheels should never be in contact with the floor; refilling with the suspension compressed leads to destruction of the air spring bellows in the suspension strut (41).

Connect STAR DIAGNOSIS and AD00.00-P- read out fault memory 2000-04A

AR32.22-P- 14 Check AIRmatic for leaks. 8100I

SUSPENSION STRUTS

Model Model Number Designation 220.025/026/028/063/065/067/070/073/074/075/125/126/128/163/165/167/170/173/174/175/176/178/179/875/878 220.083/084/087/183/184/187

Nut, rear BA32.25- suspension P-1004- Nm 20 20 strut to 04B body

Nut, rear BA32.25- suspension P-1005- strut to Nm 110 110 04B spring control arm

Pressure line, air BA32.25- suspension P-1006- Nm 5 5 to rear 04B suspension strut

SPRING CONTROL ARM

Number Designation Model 220

1st stage Nm 50 BA35.20-P-1001-01A Self-locking nut, spring control arm to rear axle carrier 2nd stage ∠° 90

THRUST ARM

Model Model Number Designation 220.025/026/028/063/065/067/070/073/075/083/084/087/125/126/128/163/165/167/170/173/175/178/183/184/187 220.074/174/176

Self- locking Nm 70 120 BA35.20- nut, P-1001- thrust 05A arm to rear axle ∠° - - carrier

THRUST ARM

Number Designation Model 220.874/875/876/878

BA35.20-P-1001-05B Self-locking nut, thrust arm to rear axle carrier Nm 120

Remove/Install Rear Suspension Strut - AR32.25-P-1016MB

MODEL 220.175 /178 with CODE (Z07) Top protection Fig 62: Identifying Rear Suspension Strut Remove/Install Components (Model 220.175)

Remove/Install

Replace self-locking Installation nuts and bolts

Special information on AH32.22-P- Model 220 AIRmatic 1000-02I

Diagnosis system STAR DIAGNOSIS Installation: Reduce pressure in rear During recharging, the wheels should never be in contact *WH58.30-Z- 1 suspension struts. with the floor; refilling with the suspension compressed leads 1048-13A to destruction of the air bellows in the suspension strut (41). Fill to 5 bar.

2 Remove rear wheel

AP40.10-P- 4050Z

AR35.20-P- 3 Remove spring link (72) 0114MB

Unplug damping unit 4 connector (Y53x1/Y54x1).

Remove cover (arrow) in 5 rear shelf.

Residual pressure in strut up to 3.5 bar. If residual Unscrew pressure line pressure valve is damaged, replace the strut (41). *BA32.25-P- 6 connection (41a). Plug the pressure line with blind plug for the duration of 1006-04B the repair operations. If pressure line or its connection fittings are damaged:↓

AR32.22-P- Recondition AIRmatic pressure line connection. 2001-02I

Do not damage C-pillar paneling. 7 Unscrew nuts (41b). Installation : Fit nuts (41b) and tighten after filling the suspension strut in the ready to drive vehicle.

*BA32.25-P- 1004-04B

Do not damage brake hose. Remove suspension 8 When installing new or used suspension struts (41), check strut (41). their condition. ↓

Check minimum installation length of suspension struts and if AR32.25-P- necessary: ↓ 1017-02I

Dispose of suspension OS32.25-P- Model 220 strut. 0122-01J

Install in the reverse 9 order

Check AIRmatic for AR32.22-P- 10 leaks. 8100I

STRUTS

Number Designation Model 220.025/026/028/063/065/067/070/073/074/075/125/126/128/163/165/167/170/173/174/175/176/178/179/875/878

BA32.25- Nut, rear P-1004- strut to Nm 20 04B body

Air BA32.25- suspension P-1006- pressure Nm 5 04B line to rear air spring

COMMERCIALLY AVAILABLE TOOLS

Number Designation

WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00

Remove/Install Rear Suspension Strut - AR32.25-P-1016N

MODEL 215

MODEL 220 with CODE (487) Active Body Control (ABC)

Fig 63: Identifying Rear Suspension Strut Remove/Install Components (Model 220 With Code (487) Active Body Control (ABC))

Remove/install

Align vehicle between the columns of the Risk of death caused by vehicle slipping or lifting platform and position the four support AS00.00-Z- toppling off of the lifting platform. plates below the hoist support points 0010-01A specified by the vehicle manufacturer.

Depressurize the hydraulic system Risk of injury to skin or eyes from hydraulic completely before starting any work on the AS00.00-Z- fluid spraying out under pressure. Risk of system. Wear protective clothing and safety 0013-01A poisoning from swallowing hydraulic fluid. glasses.

AH00.00-N- Notes on self-locking nuts and bolts 0001-01A

AH32.50-P- Notes on ABC-suspension 0001-01N

Whenever a suspension strut is replaced, the relevant plunger travel sensor must be calibrated with STAR DIAGNOSIS.

Make sure that the line of the left or right Remove cover (41e) and make a cut in the foam 1 rear plunger travel sensor (B22/1, B22/6) is insert underneath not damaged.

Separate electrical connector for left or right rear 2 plunger travel sensor (B22/1, B22/6) behind cover (41e)

*BA32.25-P- 3 Unscrew nuts (41f, 41g) on suspension strut (41) 1004-04B

4 Raise vehicle with lifting platform 5 Remove rear wheel

AP40.10-P- Remove and install wheels 4050Z

The engine must be shut off for at least 5 Open bleed screw (57) and depressurize spring minutes. 6 strut (41) Open the bleed screw (57) carefully so that hydraulic fluid can flow out slowly.

Check protective cap (41b) and replace if necessary. Remove the quick-release fitting (41a) of the Ensure that no dirt enters the open 7 hydraulic line quick-release coupling (41a). Installation: Ensure that the quick- release coupling (41a) engages properly.

The brake hose must not be disconnected from the brake caliper during the repair work. Detach brake caliper with brake pads from rear AR42.10-P- 8 To relieve the strain on the brake hose, axle 0080I fasten the rear brake caliper onto the vehicle free of tension so that it is not damaged during repair work.

9 Remove cover under spring control arm (72)

Unfasten bolted connection (41c, 41d) between *BA32.25-P- 10 suspension strut (41) and spring control arm (72) 1005-04B

Press spring control arm (72) downwards and Do not damage the boot. Do not bend 11 remove suspension strut (41) the level sensor link rod and joints!

OS32.25-P- Dispose of strut. 0122-01N

12 Install in the reverse order

AR32.50-P- 13 Fill and bleed active body control (ABC) 0021N

Risk of accident caused by vehicle starting off Secure vehicle to prevent it from moving. by itself when engine is running. Risk of injury AS00.00-Z- Wear closed and snug-fitting work clothes. caused by contusions and burns when working 0005-01A Do not grasp hot or rotating parts. in engine during starting procedure

In the event of a leak, determine and Conduct engine test run and check the ABC eliminate the cause otherwise malfunctions 14 suspension for leaks with the engine running of the ABC suspension and serious environmental pollution may occur.

STRUTS

Model Model Number Designation 215 220.025/026/028/063/065/067/070/073/074/075/125/126/128/163/165/167/170/173/174/175/176/178/179/

BA32.25- Nut, rear P-1004- strut to Nm 20 20 04B body

Nut, rear BA32.25- strut to P-1005- track Nm 110 110 04B control arm

Remove/Install The Suspension Assembly/Strut - AR32.25-P-1017

Tip: NO SCAN TOOL NEEDED TO RELEASE AIR FROM STRUTS

Remove/Install The Suspension Assembly - AR32.25-P-1017I

MODEL 220 / / / / / (except 220.083 /084 /087 /183 /184 /187) except CODE (487a) Active body control (ABC) Fig 64: Identifying Suspension Assembly Remove/Install Components (Model 220)

Remove/Install

Align vehicle between the columns of the Risk of death cased by vehicle slipping or lifting platform and position the four support AS00.00-Z- toppling off of the lifting platform. plates at the lifting platform support points 0010-01A specified by the vehicle manufacturer.

AH00.00-N- Notes on self-locking nuts and bolts 0001-01A

AH32.22-P- Special information on AIRmatic 1000-02I

1 Position the wheels straightahead

Empty suspension strut (40) affected using *WH58.30-Z- 2 Diagnosis system STAR DIAGNOSIS STAR DIAGNOSIS 1048-13A

Residual pressure in strut up to 3.5 bar. If the residual pressure valve (a) is damaged, replace the suspension strut (40). 3 Unscrew pressure line connection (40a) Plug the pressure line with blind plug for the duration of the repair operations. If pressure line or its connection fittings are damaged:↓

Repair AIRmatic pressure line connection AR32.22-P- Installation : Check pressure line O-ring 2001-02I and replace if necessary.

*BA32.25-P- 1003-04B

Installation : Fit nuts (40b) and tighten 4 Unscrew nuts (40b) on front end after filling the suspension strut in the ready to drive vehicle.

*BA32.25-P- 1001-04B

Disconnect left front axle electrical distributor connector, major assembly compartment Connectors of damping valve unit and 5 (X62/7) right front axle electrical distributor rpm sensor. Press against spring (arrow) to connector, major assembly compartment remove. (X62/6)

Installation: After installation, the bolts (40c) must close at least flush with the 6 Unscrew bolts (40c) from spring strut (40) suspension strut (40) or be slightly recessed in it.

*BA32.25-P- 1002-04B

Slacken suspension strut (40) on ball joint of Check cup seal of ball joint in spring link 7 spring link (17) using a suitable lever. (17) for damage, if necessary: ↓

AR33.15-P- Replace spring link 0170I 8 Remove spring strut (40) downwards towards the side

If replacing or reinstalling the spring AR32.25-P- struts (40), check condition of spring struts 1017-02I and if necessary: ↓

Dispose of suspension strut. OS32.25-P- Installation: When installing tighten the 0122-01I upper nuts (40b) first.

*BA32.25-P- 1001-04B

9 Install in the reverse order

Diagnosis system STAR DIAGNOSIS Fill to 5 bar. Fill the suspension strut (40) affected using During filling the wheels must not contact *WH58.30-Z- 10 STAR DIAGNOSIS the ground, as when filling in the deflected 1048-13A condition the air spring bellows in the suspension strut (40) is destroyed.

AR32.22-P- 11 Check AIRmatic for leaks. 8100I

STRUTS

Model Number Designation 220.025/026/028/063/065/067/070/073/074/075/125/126/128/163/165/167/170/173/174/175/176/178/179/875/878

Nut, front BA32.25- suspension P-1001- Nm 20 strut to 04B front end

Bolt, front BA32.25- spring strut P-1002- Nm 20 to spring 04B link

Air suspension BA32.25- pressure P-1003- Nm 5 line to front 04B suspension strut

COMMERCIALLY AVAILABLE TOOLS

Number Designation

WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00

Checking Condition Of Spring Struts - AR32.25-P-1017-02I

To ensure that the AIRmatic functions satisfactorily it is necessary to check the spring struts for damage before installing.

The boot must not be damaged (e.g. cracks).

Front axle:

Depressurized or low-pressure spring struts can be reliably recognized (not installed yet) by the insufficient length, as the tension stop spring in the shock absorber shortens the struts against an internal pressure which is too low.

It is therefore important to measure the length of the spring struts just before assembly.

The following limits apply to fitment:

Shortest length from the center of the weld seam to the end face at the bottom of the shock absorber: a ≥ 608 mm.

In addition it must be checked whether the crooked upper section of the spring strut can be tilted the other side and snapped into position at the same time. If this is not the case, the spring strut is scrap and must be replaced.

Spring struts which are too short are scrap and must not be pressurized and installed in vehicles under any circumstances. Fig 65: Identifying Front Spring Struts

Rear axle:

The rear spring struts must not be installed if the outer guide is unstable, i.e. there is a hard "metallic" stop when the outer guide is moved to and fro (arrows).