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.