2002 Mercedes-Benz S430 4.3L Eng VIN _NA_ Print Date: 7/23/2018 Basic Knowledge Suspension, General - GF32.00-P-9611C MODEL 210.081 /281 /082 /282, 168, 163, 215, 220 Complete suspension, GF32.00-P-9611- Models 210.081/082/281/282 general 01C GF32.00-P-9611- Model 168 01GC GF32.00-P-9611- Model 163 01GH GF32.00-P-9611- Model 220 01I Models 215, 220 with code 487a Active Body GF32.00-P-9611- Control (ABC) 01J Shock absorbers/front GF32.25-P-9611- Models 210.081/082/281/282 springs, general 01C Complete Suspension - General - GF32.00-P-9611-01I General The vehicle has a new, fully-supporting air suspension system on the front and rear axle which offers a soft basic suspension with a low natural frequency. In addition the full spring travel is always available when the vehicle is laden. Components: • Spring struts with integrated ADS II shock absorbers • Compressor (maintenance-free) • Central reservoir • Level control valve unit • Polyamide pressure lines (connectors guarantee easy replacement) The spring strut (40) on the front axle is attached at the bottom to the spring link (17) via two stud bolts (40c) on the ball joint and attached at the top to the body by three nuts (40b).The pressure line is connected to the residual pressure valve (40a). Fig 1: Identifying Spring Strut, Residual Pressure Valve And Stud Bolts The spring strut (41) on the rear axle is connected at the bottom with spring link (72). The upper suspension is accessible after the cover (arrow) in the rear-window shelf is removed. Fig 2: Identifying Spring Strut, Spring Link And Residual Pressure Valve The compressor unit for air suspension (A9/1) is attached on the bottom right of the longitudinal member. The level control valve unit (Y36/6) is flange-mounted to it. The central reservoir (42) is located on the left-hand side of the body. General notes on air suspension • For removal, the particular unit is to be depressurized using the Star Diagnosis tool. • Do not drain any compressed-air via the pipe connection as the compressed-air normally flows back through the air drier, regenerating the desiccant. Also refer to function description of air suspension. Fig 3: Identifying Level Control Valve Unit And Central Reservoir Torsion bars The rubber mounts for the torsion bar mount are vulcanized on the torsion bar at the front and rear axle, reducing torsion bar noise. Both torsion bars are made of solid material. The front axle torsion bar (arrow) is mounted on the front axle carrier and, via the connecting rod (23), is connected to the spring link (17) via a ball joint. The torsion bar at the rear axle is located on the rear axle carrier as on model 140. Fig 4: Identifying Spring Link And Connecting Rod Complete Suspension - General - GF32.00-P-9611-01J Models 215, 220 with code 487a Active Body Control (ABC) Fig 5: Identifying Complete Suspension Components Location General Models 215.375/378 and model 220.178 are fitted with Active Body Control (ABC) as standard. ABC is also available as special equipment for all series 220 models (except Model 220.026). As in the case of AIRmatic, hydraulic Active Body Control (ABC) is a fully-supporting suspension system with a vehicle level independent of load. The advantages are a high level of suspension/ride comfort, low level of pitching motion when starting off and braking. Rolling motions due to alternating excitation are reduced significantly even without a torsion bar at the front and rear axle. The hydraulic components are: • Oil reservoir with oil dipstick and return flow filter. • Radial piston pump with intake restrictor. • Front and rear spring struts with connection for oil pressure line and connector for movement sensor . Included in the spring strut are steel springs, spring adjustment and twin-tube shock absorbers. The spring strut fixing corresponds to models 220 with AIRmatic. • The damper adjustment valve I (HPS) and the front axle pressure reservoir is located at the bottom left of the longitudinal member. • The pressure supply valve unit is located at the bottom right of the front axle carrier. The pulsation damper is screwed into the valve unit. • The damper adjustment valve II (HPS) and the return flow pressure reservoir is attached to the left of the vehicle floor in front of the rear axle. • The rear axle pressure reservoir is secured on the rear right of the underbody. • The oil cooler is located upstream of the condensor/air conditioning. • The bleed screws for draining the hydraulic fluid for repair work are attached in the pressure line to the spring strut. The vehicle level is recorded at the control arm at the front axle and at the spring link at the rear axle and conveyed to the control module. The level at the individual spring struts is controlled by four control valves in the adjustment valves. The pressure oil is supplied by the radial piston pump via the adjustment valves in the individual spring struts. Also refer to detailed function description of Active Body Control (ABC). Notes on repair The filling quantities of the ABC system are approx. 4.0 liters when refilling. The oil reservoir (2) for the ABC system must only be filled with special hydraulic fluid in accordance with "Sheet 345.0 of MB Specifications for Service Products" (part no. A 001 989 24 03). The oil reservoir (2) for the power steering pump is located separately but is filled with the same special hydraulic fluid. • When working on the ABC system the area of the oil pressure line connections of the components to be removed should be cleaned before starting the repair and machining residues, e.g. shavings and fluff must not enter the system. • Drain hydraulic fluid via the particular bleed screw and dispose of the fluid. • Pay great attention to cleanliness when filling as the smallest dirt particles can result in the failure of Active Body Control. • When bleeding with the engine running always ensure that there is sufficient hydraulic fluid in the oil reservoir and that the radial piston pump does not draw any air into the system. • To bleed the ABC system, operate the level switch several times with the engine running, with the vehicle raised and lowered. This means that any air can escape from the system. Fig 6: Identifying Oil Reservoir AIRmatic, Function - GF32.22-P-0003A MODEL 220 except CODE (487a) Active body control (ABC) Fig 7: AIRmatic System Diagram Fig 8: AIRmatic Block Flow Chart The AIRmatic system is a fully supporting air suspension system. The system provides both static and dynamic support by means of four air bellows located at the wheels. The AIRmatic system also features the following additional functions: • The level control allows both manual and speed-responsive, automatic raising/lowering of the vehicle level. • The electronic level control system controls the vehicle level at the front and rear axles and ensures the vehicle level remains constant according to the driving and vehicle loading conditions. • The "A daptive D amping S ystem" (ADS ) changes the damping forces according to the road conditions and driving style of the driver. The road conditions are determined by vertical acceleration pickups at the body of the vehicle. The driving style (horizontal acceleration) is calculated using the vehicle speed and turn angle. Phased in as of 09/00, the damping is set to the sporty damping level at vehicle speeds >160 km/h. Advantages • Higher level of driving safety and ride comfort due to: ◦ Adapting damping to road conditions and driving style. ◦ Low location of center of gravity. ◦ Low aerodynamic drag and therefore low fuel consumption. ◦ Less lift at front axle. • Individual adaptation due to: ◦ Raising vehicle level for poor road surfaces or driveways. ◦ (Up to 08/99) 2 possible damping levels for comfortable or sporty driving style. (As of 09/99) 3 possible damping levels for comfortable, sporty or extremely sporty driving style. • Driver information: ◦ Higher vehicle level and sporty damping level displayed by means of indicator lamps in switches. ◦ Warning appears on multifunction display in instrument cluster if vehicle level is too low. Fig 9: AIRmatic Function Communication Diagram Function overview The functions of the pneumatic closed loops are controlled using the components of the electric/electronic system. The AIRmatic control module receives input signals from the following components: • ESP control module (via CAN) • Engine control module (via CAN) • Transmission control module (via CAN) • Instrument cluster (via CAN) • Steering angle sensor (via CAN) • ADS comfort and sport switch (via CAN) • Level adjustment switch (via CAN) • 3 body acceleration sensors • 2 front axle level sensors • 1 rear axle level sensor • 1 AIRmatic pressure sensor • Voltage supply and ground Main reservoir charge valve (y5) In the AIRmatic control module, the input signals are converted into output signals for the following components: • 4 level control valves • 1 main reservoir charge valve • 4 ADS damper valves (each with 2 solenoid valves) • Multifunction display in instrument cluster • Indicator lamps in switches: ADS comfort and sport, level adjustment • Air compressor The AIRmatic control module uses the input signals to decide which of the 3 functions must be controlled: • Level adjustment • Level control • ADS Several control functions can be processed at the same time. GF32.22-P-0003- AIRmatic driver information up to 31.8.1999 01A GF32.22-P-0003- as of 1.9.1999 01B AIRmatic, location of pneumatic/hydraulic GF32.22-P-0003- components 02A AIRmatic, location of electric/electronic GF32.22-P-0003- components 03A AIRmatic control module CAN signals AD32.22-P-2000- 04A Level adjustment, function GF32.22-P-4005A Model 220 except AIRmatic level adjustment, function GF32.22-P-4004B Model 220 GF32.22-P-4004C Adaptive damping system (ADS II), function GF32.32-P-0001B AIRmatic Driver Information - GF32.22-P-0003-01A Various messages and indications for AIRmatic and ADS are displayed on the multifunction display in the instrument cluster as well as in the comfort and sport switches.