ah32.22-p-1000-02i notes on airmatic model 220

AH32.22-P-1000-02I Notes on AIRmatic Model 220 p

P32.22-2083-09

40 Front spring strut41 Rear spring strut42 Central reservoir

B22/3 Rear axle level sensorY36/6 Level control valve unit

A9/1 AIRmatic compressor unitB22/8 Left front level sensorB22/9 Right front level sensor

P32.22-2053-05

Connections for:1VL Valve unit pressure line - left front

spring strut2VL Valve unit pressure line - right

front spring strut3HL Valve unit pressure line - left rear

spring strut4HR Valve unit pressure line - right rear

spring strut5SP Valve unit pressure line - central

reservoirP Valve unit pressure line -

AIRmatic compressor unit

B7 AIRmatic pressure sensorY36/6 Level control valve unitY36/6x1 Valve unit connector

Copyright DaimlerChrysler AG 24.03.2009 CD-Ausgabe G/08/04 . This WIS print-out will not be recorded by Modification services.

p , 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.

iThe emergency-running buffers may only be used for manoeuvering

Copyright DaimlerChrysler AG 24.03.2009 CD-Ausgabe G/08/04 . This WIS print-out will not be recorded by Modification services.

AR32.22-P-1600I Seal top air suspension strut 22.5.03

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

P32.22-2273-06

Shown on right air suspension strut

1 Pressure line connection2 Residual pressure retaining valve3 Circlip4 Cover5 Nuts6 Bolt M8

P32.22-2272-07

010 Removal and installation tool 010a Bolt

P32.22-2271-07

7 Bellows of air suspension strut

e Remove

a Danger! Risk of death cased by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

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

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

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

3 Discharge air suspension struts using STAR DIAGNOSIS

Diagnosis system STAR DIAGNOSIS *WE58.40-Z-1013-06A

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

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

Copyright DaimlerChrysler AG 24.03.2009 CD-Ausgabe G/08/04 . This WIS print-out will not be recorded by Modification services. Page 1

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

a Danger! Risk of injury to skin and eyes from handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

6 Warm up casting compound with hot air bloweri Heat adhesive until it softens. At the same time check the hardness with a screwdriver.k Hot air blower *WH58.30-Z-1014-20A

7 Separate casting compound with screwdriver i Always remove separated parts of the casting compound with dust extractor.

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

9 Always remove remaining casting compound with screwdriver

i There must be no burrs and dirt particles.

10 Screw in bolts (010a) of the removal and installation tool (010) in stages, corresponding to the picture sequence and secure with cotter pins

p Only one nut (5) must always be released and replaced by a bolt (010a) of the removal and installation tool (010). When releasing several nuts (5), the air suspension strut can slip out toward bottom and can be damaged.i Installation: Replace nuts (5)

l Removal/installation tool *220589006100

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

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

13 Release removal and installation tool (010) and remove cover (4) with bar magnet

g Check surfaces at air suspension strut and the groove of the circlip (3) for sharp edges. Remove sharp edges if required.

d Install

14 Insert new cover (4) i Apply grease paste onto the sealing ring of the new cover (4)p 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.

15 Press in cover (4) with removal and installation tool (010)

p When pressing in, ensure that the new cover (4) is pressed in evenly and is not tilted. Otherwise the sealing ring of the cover (4) is damaged and this leads to the leakage of the air suspension strut.

16 Fit circlip (3) i Replace locking ring (3).17 Pull out cotter pins of the bolts (010a) of the

removal and installation tool (010) and detach bolts (010a) in stages in the reverse installation sequence

p Fit on nuts (5) by hand and after filling the air suspension strut tighten in curb condition.

p Only one nut (5) must always be released and replaced by a bolt (010a) of the removal and installation tool (010). When several bolts (010a) are loosened the air suspension strut can slip out downwards and be damaged.n *BA32.25-P-1001-04B

18 Mask air suspension strut dome in engine compartment

i The surfaces must be free of grease before painting.

a Danger! Risk of explosion from paint vapors igniting. Paint fumes are poisonous when inhaled.

No smoking! No open flames! Use respiratory protection, protective clothing, gloves, safety goggles and skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

19 Coat damaged surfaces at air suspension top section with priming filler and paint with black acrylic paint

i Let painted surfaces dry.

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

20 Unscrew bolt M8 (6) from opening of residual pressure retaining valve (2) and screw in new residual pressure retaining valve (2)

i Fit on residual pressure retaining valve (2) by hand and tighten with suitable tool.

21 Screw on pressure line connection (1) i Check O-ring of pressure line for damage and replace if required.n *BA32.25-P-1003-04B

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


23 Align bellows (7), for this step press the bellows (7) toward top and pull in released position toward bottom.

p When working on the air suspension strut, unintended wrinkle formations at the bellows (7) can occur. The wrinkle formations must be eliminated, otherwise this can lead later to a failure of the air suspension.

24 Pressurize air suspension strut using STAR DIAGNOSIS

p The wheels must not be in contact with the ground during the filling. When filling in deflected condition, the air suspension bellows is destroyed inside the air suspension strut.i When filling, the lower support bearing must be pulled to the bottom, so that no air can escape from there.Diagnosis system STAR DIAGNOSIS *WE58.40-Z-1013-06A

25 Check top air suspension strut for leaks i Spray repaired point with soap water. Pay attention to bubble formation during the rocking at front end.

AR32.22-P-8100I

n 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

Models 220.083/084/087/183/184/187

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

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

Nm 5 5

Removal, installation

220 589 00 61 00

Commercially available tools (see Workshop Equipment Manual)

Number Designation Make (e. g.) Order numberWH58.30-Z-1014-20A Hot-air gun - 3000 W Firma Zinser

SchweißtechnikGmbHPostfach 14 40 73061 Ebersbach/FilsTel.: 07163/16710

Model K-25-R

Workshop equipment/MB testers (see Workshop Equipment Manual)

WE58.40-Z-1013-06A Diagnostic system STAR DIAGNOSIS, compact passenger vehicle, order number 6511 1801 00


GF32.25-P-1000-03A Spring strut, function Model 220 n

P32.22-2006-79

The weight of the vehicle is carried by the compressible air (l) sealed into the air bellows of the spring struts. The rolling hose air bellows (h) is made of rubber. Under dynamic load during driving, the air bellows rolls up parallel with the axis of the spring strut, thus providing the necessary spring travel. The rollup zone on the spring strut is sealed off from the outside by a rubber boot (n) as a protection against dirt.

The vehicle level is raised/lowered by increasing/reducing the air pressure in the air chamber (l), which results in a lengthening/shortening of the spring strut (40).The spring strut incorporates a residual pressure valve (k) which blocks off the pressure chamber in the spring strut in the direction of the supply line in the event of a pressure drop at or below a residual pressure of 4-5 bar.


GF32.25-P-1000-02A Spring strut, design Model 220 n

P32.22-2007-79

41 Rear axle spring struta Strut tubeb Cylindrical tubec Piston rod gasketd Piston rod guide

k Residual pressure valvel Air chamberm Dividing pistonn Protective boot0 Gas pressure chamber

e Piston rodf Working pistong Rebound buffer springh Air bellowsi Stop buffer

A single-tube gas-filled shock absorber is integrated into the spring strut.

The ADS damper valve is attached to the spring strut.


ah32.22-p-1000-02i notes on airmatic model 220

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