AH32.

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

P32.22-2083-09
40 Front spring strut A9/1 AIRmatic compressor unit B22/3 Rear axle level sensor
41 Rear spring strut B22/8 Left front level sensor Y36/6 Level control valve unit
42 Central reservoir B22/9 Right front level sensor
Connections for:
1VL Valve unit pressure line - left front
spring strut
2VL Valve unit pressure line - right
front spring strut
3HL Valve unit pressure line - left rear
spring strut
4HR Valve unit pressure line - right rear
spring strut
5SP Valve unit pressure line - central
reservoir
P Valve unit pressure line -
AIRmatic compressor unit

B7 AIRmatic pressure sensor

Y36/6 Level control valve unit
Y36/6x1 Valve unit connector

P32.22-2053-05

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 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.
Copyright DaimlerChrysler AG 24.03.2009 CD-Ausgabe G/08/04 . This WIS print-out will not be recorded by Modification services.
 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.
i
The emergency-running buffers may only be used for
manoeuvering
Page 2
 AR32.22-P-1600I Seal top air suspension strut 22.5.03

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

Shown on right air suspension strut

1 Pressure line connection

2 Residual pressure retaining valve
3 Circlip
4 Cover
5 Nuts
6 Bolt M8

P32.22-2273-06

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 Align vehicle between the columns of the AS00.00-Z-0010-01A
toppling off of the lifting platform. lifting platform and position the four support
plates at the lifting platform support points
specified by the vehicle manufacturer.
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 system STAR DIAGNOSIS *WE58.40-Z-1013-06A
DIAGNOSIS
p Special information on AIRmatic AH32.22-P-1000-02I
4 Unscrew pressure line connection (1) and
place pressure line to the side
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 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 Wear safety gloves, protective clothing and AS00.00-Z-0002-01A
hot or glowing objects. safety glasses, if necessary.
6 Warm up casting compound with hot air blower i 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 i There must be no burrs and dirt particles.
with screwdriver
10 Screw in bolts (010a) of the removal and p Only one nut (5) must always be released
installation tool (010) in stages, corresponding and replaced by a bolt (010a) of the removal
to the picture sequence and secure with and installation tool (010). When releasing
cotter pins 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) g Check surfaces at air suspension strut
and remove cover (4) with bar magnet 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 p When pressing in, ensure that the new
installation tool (010) 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 p Fit on nuts (5) by hand and after filling the
removal and installation tool (010) and detach air suspension strut tighten in curb condition.
bolts (010a) in stages in the reverse
installation sequence
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 i The surfaces must be free of grease
compartment before painting.
a Danger! Risk of explosion from paint vapors igniting. No smoking! No open flames! Use respiratory AS98.00-Z-0002-01A
Paint fumes are poisonous when inhaled. protection, protective clothing, gloves, safety
goggles and skin cream. Ensure that the area
is well ventilated.
19 Coat damaged surfaces at air suspension top i Let painted surfaces dry.
section with priming filler and paint with black
acrylic paint
p Notes on paintwork repairs AH98.00-P-9408-02A
20 Unscrew bolt M8 (6) from opening of residual i Fit on residual pressure retaining valve (2)
pressure retaining valve (2) and screw in new by hand and tighten with suitable tool.
residual pressure retaining valve (2)
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.

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 23 Align bellows (7), for this step press the
bellows (7) toward top and pull in released
position toward bottom.
24 Pressurize air suspension strut using STAR
DIAGNOSIS
25 Check top air suspension strut for leaks
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.
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
i Spray repaired point with soap water. Pay AR32.22-P-8100I
attention to bubble formation during the
rocking at front end.

n Struts

Number Designation Model Models

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

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 Nm 5 5

strut

220 589 00 61 00

Removal, installation

Commercially available tools (see Workshop Equipment Manual)

Number Designation Make (e. g.) Order number
WH58.30-Z-1014-20A Hot-air gun - 3000 W Firma Zinser Model K-25-R
Schweißtechnik
GmbH
Postfach 14 40
73061 Ebersbach/Fils
Tel.: 07163/16710

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

Copyright DaimlerChrysler AG 24.03.2009 CD-Ausgabe G/08/04 . This WIS print-out will not be recorded by Modification services. Page 3
 GF32.25-P-1000-03A Spring strut, function
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.
Copyright DaimlerChrysler AG 24.03.2009 CD-Ausgabe G/08/04 . This WIS print-out will not be recorded by Modification services.
Model 220 n
P32.22-2006-79
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.
Page 1
 GF32.25-P-1000-02A Spring strut, design Model 220 n

P32.22-2007-79
41 Rear axle spring strut e Piston rod k Residual pressure valve
a Strut tube f Working piston l Air chamber
b Cylindrical tube g Rebound buffer spring m Dividing piston
c Piston rod gasket h Air bellows n Protective boot
d Piston rod guide i Stop buffer 0 Gas pressure chamber

A single-tube gas-filled shock absorber is integrated into the spring The ADS damper valve is attached to the spring strut.
strut.

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