1994 S320 S420 S500 Owner's Manual

12/18/2016 AirmaticW220Encyclopedia
Airmatic
FromW220Encyclopedia
Contents
1IntroductionAIRmatic
2DescriptionAIRmatic
3IdentificationofFrontStrutsAIRmatic
4FeaturesAIRmatic
5AdvantagesAIRmatic
6FunctionAIRmatic
6.1PressureSupplyFunctionAIRmatic
6.2LevelControlFunctionAIRmatic
7ComponentsAIRmatic
7.1AIRmaticCompressorUnit(A9/1)
7.1.1DesignAIRmaticCompressorUnit
7.1.2FunctionAIRmaticCompressorUnit
7.1.3AirFilter/CleanerAIRmatic
7.1.4PartNumbersAIRmaticCompressorUnit
7.1.4.1AIRmaticCompressorUnit
7.1.4.2AirFilter/CleanerAIRmatic
7.1.4.3AirFilter/CleanerProtectiveBootAIRmatic
7.2LevelControlValveUnit(Y36/6)AIRmatic
7.2.1DesignAIRmaticLevelControlValveUnit(Y36/6)
7.2.2AirLineColourCodesLevelControlValveUnit(Y36/6)
7.2.3AirLineDesignationsLevelControlValveUnit(Y36/6)
7.2.4FunctionAIRmaticLevelControlValveUnit
7.2.5PartNumberAIRmaticLevelControlValveUnit
7.3AIRmaticPressureSensor(B7)
7.3.1FunctionAIRmaticPressureSensor(B7)
7.4LevelSensor(B22/3,B22/8,B22/9)
7.5AIRmaticCentralReservoir(42)
7.6Comfortandsportswitch(N72/1s3)
7.7Levelcontrolswitch(N72/1s2)
7.8ControlModule(N51)AIRmaticwithADS
7.8.1FunctionAIRmaticwithADSControlModule(N51)
7.8.2LocationAIRmaticwithADSControlModule(N51)
7.8.3InputFunctionsAIRmaticwithADSControlModule(N51)
7.8.4OutputFunctionsAIRmaticwithADSControlModule(N51)
7.9CompressorRelay(K40/7kO)AIRmatic
7.10AirSuspensionSpringStrut(40,41)AIRmatic
7.10.1DesignAirSuspensionSpringStruts(40,41)
7.10.1.1DesignFrontAxleSpringStrut(40)
7.10.1.1.1ProtectiveBootorBellowsFrontAxleAirSpringStrut(40)
7.10.1.1.2AirSpringPlungerandSupportBushingFrontAxleSpringStrut(40)
7.10.2OperationAirSpringStruts(40,41)
7.10.3FunctionAirSpringStruts(40,41)
7.10.4PartNumbersAIRmaticAirSpringStruts(40,41)
7.10.4.1OEMAIRmaticAirSpringStruts(40,41)
7.10.4.2OE(Bilstein)AIRmaticAirSpringStruts(40,41)
7.10.4.3ArnottAIRmaticAirSpringStruts(40,41)
7.11AdaptiveDampingSystem(ADSII)AIRmatic
7.11.1FunctionAdaptiveDampingSystem(ADSII)
7.11.1.1DesignDampingValveUnit(Y51,Y52,Y53,Y54)
7.11.1.2ComponentsDampingValveUnit(Y51,Y52,Y53,Y54)
7.11.2ForceSettingsAdaptiveDampingSystem(ADSII)
7.12Multifunctiondisplay(A1p13)
8IssuesandTroubleshootingAIRmatic
8.1"AIRMATICVISITWORKSHOP!"messageontheinstrumentcluster
8.2"AIRMATICSTOP,CARTOOLOW!"messageontheinstrumentcluster
8.3VehicleLevelTooLow
8.3.1AirBag/BladderLeaking
8.3.2HeightMeasuringTechnique
8.3.3LeakageSpecification
8.3.4TopSealsLeaking
8.3.5RepairOptionsAIRmaticAirSuspensionStrut
8.3.6AIRmaticCompressorUnitFailure
8.3.7PressureLinesLeaking
8.3.8LevelControlValveUnitLeaking
8.3.9CentralReservoirLeaking
8.3.10LevelSensorFaulty
8.4VehicleLevelTooHigh
8.4.1LevelControlValveUnitLeakingVehicleTooHigh
8.4.2LevelSensorFailure
8.4.3ValveFailureRearSuspensionStrut
8.5ProtectiveBoot/BellowsFailure
8.6UpperMountRubberBushFailure
8.6.1PartNumberUpperMountRubberBush
9EmergencyProcedureAIRmatic
9.1Originallimphomebuffers
9.1.1Frontaxle
9.1.2Rearaxle
10TipsAIRmatic
11DIYRepairsAIRmatic
11.1ReplacingRelayK40/7kOAIRmatic
11.2InspectingAIRmaticLevelControlValveUnit(Y36/6)forleaks
11.2.1GeneralleaktestingLevelControlValveUnit(Y36/6)
https://w220.ee/Airmatic 1/44
11.2.1GeneralleaktestingLevelControlValveUnit(Y36/6)
11.2.1.1LeakTestingUsingSDS
11.2.1.2SampleResultsofLeakTestingUsingSDS
11.2.1.3LeakTestingWithoutSTAR
11.2.2TestforinternalleakLevelControlValveUnit(Y36/6)
11.3ReplacingCompressorUnitAIRmatic
11.4LineRepairAIRmatic
11.5LeakingFrontStrutAirSpringRepairOptions
11.5.1CommonIssueLeakingFrontStrutAirSpring
11.5.2LeakTestLeakingFrontStrut
11.5.3RepairOptionsLeakingFrontStrut
11.6ReplacingFrontAxleSpringStrut(40)AIRmatic
11.6.1RemovalReplacingFrontAxleAIRmaticSpringStrut(40)
11.6.2InstallationReplacingFrontAxleAIRmaticSpringStrut(40)
11.6.3TutorialsReplacingFrontAxleSpringStrut(40)
11.7ReplacingRearAxleSpringStrut(41)AIRmatic
11.7.1PartsDesignationsReplacingRearAxleAIRmaticSpringStrut(41)
11.7.2RemovalReplacingRearAxleAIRmaticSpringStrut(41)
11.7.3InstallationReplacingRearAxleAIRmaticSpringStrut(41)
11.8ReplacingtheAirSpringinanAIRmaticStrut
11.8.1DismantlingFrontAirSpring
11.8.2ReassemblyFrontAirSuspensionStrut(40)
11.8.3ToolsRequiredReplacingAirSpringinFrontAirSuspensionStrut(40)
IntroductionAIRmatic
AllW220vehiclescomewithAirmaticpneumaticsuspensionsystem,unlessvehiclehasoptioncode487inwhichcasethevehicleisequippedwithActiveBodyControl
(ABC)hydraulicsuspensionsystemwithadditionalcomputercontrol.ABCsystemprovidesgreaterrollcontrolandeliminatesany"nosedive"evenwithheavybraking(not
thatthereismuchofeitherwithAirmatic).BothsuspensionsystemsareresponsibleforthesuperbrideandhandlingoftheW220andbeingcomplexsystemswillrequire
maintenance.
Airmaticsystemsonearliercarstendedtofailmoreoftenthanonthe'03andlaterthe'04sandonarelessproblematic.However,thereisnosuchthinga"bulletproof"
pneumaticsuspensionsystem.Sealsandpumpswillwear,andstrutswillhavetobereplaced.You'dhavetodothesamethingwithstandardshocks,toobutAirmaticwill
bemoreexpensive.ThebestprotectionistobecomefamiliarwiththeearlysignsofAirmaticproblems,andfixthemrightaway.Lettingthemgorunsthecostup.
Theyarenotespeciallyproblematic,butlikeanycomplexsystem,theybreakandanyluxurycarisexpensivetorepair.Keepinmindthatifthegarageyouusedoesnot
haveSTARDiagnosticsandcannotinterpretthevaluesbothinsensorvoltageandothertests,thendon'twasteyourtimeandmoney.Findsomeonewhocan.DIYis
possiblebutpreferablyrequiresuseofSTARDiagnosticswithsomepriorexperienceandalwayslotsofpatience.
Onecommonfailurepointwhichwasinitiallysubjecttoinspectionandfreereplacement,wasthehighpressurelinefromthepumptothevalvebody.
Anothercommonweaknessinthepre'03ishW220'scomparedtothosefromafewyearslater,isthesealsatthetopsofthefrontsuspensionstruts.Theolderdesigncan
leakairovertime.Thenewermodelsandoneswithnewreplacementpartsdonotleak.Carsthatwereunderwarrantycouldhavethesesealsreplacedwiththatcoverage.
Otherissuesareshownbelow.
DescriptionAIRmatic
TheW220AIRmaticsystemisafullysupportingairsuspensionsystemwhichprovidesbothstaticanddynamicsupportbymeansoffourairstrutslocatedatthewheels.
Eachstruthasanairspringcontaininganairbag(bladder)andadampenerbuiltintotheoneunit.Thestrutsgetairviaavalvedistributionunitfromanaircompressor
locatedbehindthefrontbumperclosetothefrontrightwheelwell.Ontheoppositesideisthecentralreservoirwhichstoresairpressureforusewhenthepumpisnot
running.Thevalveunitisconnectedtoacomputerwhichmonitorstheairpressure,thevehicleweight,thevehicleheightrequirementandvehiclestance(angle)andthen
setstherideheightaccordingly.
IdentificationofFrontStrutsAIRmatic
ToidentifyearlyandlatertypesofW220frontstrutsinspectthetopofthefrontstrutwheretheairpipeconnects.
Thisistheoriginaloldeststylefrontstrut(usedin'00andearly'01)whichdidnothavetheepoxy.
FrontstrutsonW220suptoabout2004didhaveepoxyinstalledatthefactory.Alsomanyoftheolderstylefrontstruthavenowbeenmodifiedwithmasticorepoxyadded.
Note:Theepoxyisnotthesealfortheupperstrut.Itisavibrationdampertohelpthenarrowneckofthebrassvalveatthetopofthestrutavoidcrackingandleakingdueto
vibration.Ifyouhavealeakinthisolderstylefrontstrutthereisakityoucanbuytofixtheleak.(Seebelow.)Scrapingouttheoldblackepoxyandfillingitbackinwill
notfixthis.Thepartthatleaksisahalfmetalandrubbercapundertheblackepoxyandissecuredwithametallockring.
Thenextfigureshowsthenewerstylefrontstrutwithmastic.Thenewersealshaverubbermasticcompoundpouredinthecentertosealthecircumferenceoftheupper
metalcapontheupperpartofthefrontstrutandtokeepthebrassfittingfrombreakingoff.
FeaturesAIRmatic
Levelcontrolbothmanualandspeedsensitive.
Electroniclevelcontrolwhichmaintainsaconstantevenlevelatthefrontandrearaxlesaccordingtothedrivingandvehicleloadconditions.
Whenthevehicleisstationarythelevelisreadjustedifthereisadifferenceofmorethan+/10mmafteradoororthetrunklidisopened.
Whiledrivingthelevelisreadjustedifthereisadifferenceofmorethan+/20mm.Thelevelisadjustedto+/10mmevery15minutes.
ActiveDampingSystem(ADS)whichchangesthedampingforcesaccordingtotheroadconditionsandthedriver'sdrivingstyle.Theroadconditionsaredetermined
byverticalaccelerationsensorsinthebodyofthevehicle.Thehorizontalaccelerationisdeterminedbymeasuringthevehiclespeedandturnangle.
AdvantagesAIRmatic
Higherlevelofdrivingsafetyandridecomfortdueto:
Adaptingdampingtoroadconditionsanddrivingstyle.
Lowlocationofcentreofgravityasvehiclelowersabove70KPH.
Lowaerodynamicdragandfuelconsumptionasvehiclelowersabove70KPH.
Lesstendencyforvehicletoliftatspeed.
Individualadaptationdueto:
Raisingvehiclelevelforpoorroadsurfacesandwhennegotiatingdriveways.
Twopossibledampinglevelsforcomfortorsportdrivingstylesinvehiclesproducedupto08/99.
Threepossibledampinglevelsforcomfort,sportorextremesportdrivingstylesinvehiclesproducedafter09/99.
Driverinformationdueto:
Vehicleleveldisplayedbyindicatorlampsandswitches.
Warningmessagesinmultifunctiondisplayifvehicleistoolow.
FunctionAIRmatic
ThefunctionsoftheAIRmaticwithAdaptiveDampingSystem(ADS)controlmodulearedividedasfollows:
Signalconditioning
Signalconditioning
Functionlogiccomponent
Safetycircuit
Signalconditioning
Thefollowinginputsignalsareprocessedbythefunctionlogiccomponentandusedforcalculationsortoprovideinformation:
Calculationofbodyverticalacceleration
Signalfrombodyaccelerationsensors
Calculationofvehiclespeed
Wheelspeedsignal
Speedstatussignal
Calculationoflongitudinalandlateralacceleration
Wheelspeedsignal
Signalfromsteeringanglesensor
Calculationofcompressorcontrol
Outsidetemperature,outsideairpressuresignal
Reservoirpressuresignal
Vehiclespeedsignal
Vehiclelevelsignal
Dutycycle
Calculationforvalvecontrol
Levelsignalfromleftfrontaxle,rightfrontaxle
Rearaxlelevelsignal
Calculationforcontrolofmainreservoirchargevalve
Levelsignalfromleftfrontaxle,rightfrontaxle
Rearaxle
Pressuresignal
Calculationofvehiclelevel
Signalfromlevelsensors
Informationsignals(control)
Signalfromstoplampswitch
Signalfromcomfortandsportswitch
Signalfromlevelcontrolswitch
Signalfromdoorcontactswitch,trunk,remotecontrol
Functionlogiccomponent
Theconditionedinputsignalsareprocessedinthelogiccomponentandconvertedintooutputsignals.
Signalfrombodyaccelerationsensors(B24/3,B24/8,B24/9):
Theverticalaccelerationofthevehicleiscalculatedusingthesignalsfromthebodyaccelerationsensors.
Frontwheelspeedsignal,leftandright:
Usingthewheelspeedsignal,theESPcontrolmodulecalculates
Vehiclespeed
Longitudinalacceleration
Vehiclestatus.Adistinctionismadebetweenamovingandastationaryvehicle.Incorrectwheelspeedsignalsarealsodetected.
Steeringanglesensorsignal(N49):
Thelateralaccelerationofthevehicleiscalculatedusingthesteeringanglesensorsignalandthewheelspeedsignal.
Signalfromlevelsensors(B22/8,B22/9,B22/3):
Bothfrontaxlelevelsensorseachsupply2signals.Thesensorsdetectandtransferthedistancebetweenthewheelcenterandthebodyatboththeleftandright
handsideofthevehicle.
Therearaxlelevelsensorsupplies2signals.Thesensordetectsandtransfersthedistancebetweenthewheelcenterandthebody(averagecalculatedfromleft
andrightwheel).
Brakelampswitchsignal(S9/1):
Whenthedriverpressesthebrakepedal,asignalisreceivedbytheADSlogiccomponentandthedampingatallwheelsissetto"hard".Thepitchmotionof
thevehiclewhenbrakingcanthereforebereduced.
Comfortandsportswitchsignal(N72/1s3):
Thecomfortandsportswitchsignalinformsthesystemabouttheselectionmadebythedriverbetweenonecomfortorientedand2sportydampingmaps.The
"comfort"settingmaintainsthedampingwithinthecomfortablerangeasfarasthedrivingstyleandroadconditionswillallow.The"Sport1"settingmakesthe
dampingsomewhat"harder".The"Sport2"settingimmediatelysetsthedampingforceto"hard".Thedriver'spreferredsettingsarestoreduntilchangedbythe
driver(evenwithIgnitionOFF).
Signalfromleveladjustmentswitch(N72/1s2):
Thecontrolmoduleusesthesignalsfromtheleveladjustmentswitchtodeterminethedriver'spreferencesforthevehiclelevel:
Normallevel
Raisedlevel
ADSII
Thecontrolmoduleusestheverticalbodyacceleration,longitudinalandlateralaccelerationofthevehicleandthegroundspeedtodeterminetheoptimumlevel
ofdamping.4differentdampingforcescanbesetateachwheelbycontrollingthedampingvalveslocatedateachwheel.Phasedinasof09/00,thedampingis
settotheSport1dampinglevelifthevehiclespeedis>160km/h.
Levelcontrolandadjustment
Thecontrolmoduleusesthesettingoftheleveladjustmentswitchselectedbythedriverandthegroundspeedofthevehicletocontroltheappropriatelevel
controlvalvesandtosetthecorrectvehiclelevelaccordingtothevehicleload.
TheAIRmaticsystemisequippedwithapressurereservoirtokeepthelevelcontroltimeasshortaspossible(e.g.afterloading).Thereservoirpressureisused
onlywhenrequiredinordertopreventfillingthereservoirtoooften.Thishappens,forexampleifthevehiclelevelfallsbelowacriticallevelwhenloadingthe
vehicleorifthedriverhassetthevehiclelevelto"raisedlevel".Pressurefromthereservoirisalsousedwhenthevehicleisstationarytominimizenoise.With
normalcontrolwhenthevehicleismoving,thespringstrutsaresupplieddirectlybytheaircompressor.
Mainreservoirpressurecontrol
Themaincontrolparametersarethepressureinthemainreservoir,theoutsideairpressureandthevehiclespeed.
Compressorcontrol
Thecompressoriscontrolledviaarelay.Sincethecompressorisnotdesignedforcontinuousoperation,theabsoluterunningtimeandcoolingphaseare
monitoredtoavoidoverloadingthecompressor.
Wakeupfunction
Aparkedvehicleis"wokenup"beforetheengineisstarted.Thatistosay,theAIRmaticwithADScontrolmodulereceivessignalsfromthedoorcontactswitches,the
trunkswitchandinfraredremotecontrolindicatingthatthedrivermaysoonstarttheengineanddrivethevehicle.Thecurrentvehiclelevelischeckedimmediatelyand
correctedifrequired.Thevehiclelevelatthefrontaxleisconsideredtobecritical,forinstance,ifthefullwheelanglecannolongerbeguaranteed.Inthiscaseamessage
appearsonthemultifunctiondisplayintheinstrumentclustertowarnthedriver:"Stopcartoolow".Ifthecontrolmoduleiswoken(forexamplebyopeningoneofthe
doors),therefollowsaperiodofsparetimebeforethedriveractuallystartstheengineduringwhichthevehicleleveliscorrected.Thisreducesthewaitingtimerequiredto
correctthevehiclelevelandthevehicleisreadyfordrivingmorepromptly.Pressureinthemainreservoirisusedtoraisethestationaryvehicle.Thecompressorisonly
usedifthepressurereservoirisempty.Itmustbeensuredthatthebatteryvoltageissufficienttothenstarttheengine.
Lockingfunction
Ifthecontrolmoduledetectsthatallwheelsareunloadedwhenthevehicleisstationary,thevalvesofthesprintstrutsareclosed.Thevehiclethereforeremainsatthe
currentlevel.Thisisessential,forexample,whenchangingawheelorduringrepairwork(liftingplatform).
Safetycircuit
TheAIRmaticwithADScontrolmodulemonitorsalltheimportantcomponentsofthesystemaftertheyareswitchedonandduringoperation.Thesafetycircuitdetects
faultysignalsfromsensors,faultsinthecontrolmoduleandintheelectriclinesystem.Ifafaultisdetected,thesystemisswitchedoffandamessageisdisplayedonthe
multifunctiondisplayintheinstrumentclustertowarnthedriver.ThedampervalvesforADSarenolongercontrolledandremainsettothe"hard"dampinglevel(driving
safetylevel).Inaddition,afaultcodeisstoredinthecontrolmodule.Thelevelcontrolispartiallyswitchedoffdependingonthefaultthatoccurred.Thesystemalways
strivestomaintaintheselectedvehiclelevel.Moreover,thesafetycircuitcontinuouslymonitorsthebatteryvoltage.Ifthevoltagefallsbelow10.5Vorexceeds17.5V,the
systemisswitchedoffuntilthevoltagereturnstothespecifiedrange.
PressureSupplyFunctionAIRmatic
42AIRmaticCentralReservoir
A9/1AIRmaticCompressorUnit
Y36/6LevelControlValveUnit
Innormaldrivingmode,AIRmaticworkswithapressureofbetween6and10bar(600and1,000KPaor87and145psi)dependingontheload.Anelectricalcompressoris
usedtosupplypressure.ThisisinstalledintheAIRmaticCompressorUnit(A9/1).
InadditionthesystemhasanAIRmaticCentralReservoir(42)whichstoresthecompressedair.TheAIRmaticCentralReservoir(42)pressureisbetween13and16bar
(1,300and1,600KPaor189and232psi)(atsealevel).
TheAIRmaticsystemiseithersuppliedwithpressureviatheAIRmaticCentralReservoir(42)orviatheAIRmaticCompressorUnit(A9/1).
LevelControlFunctionAIRmatic
TheAIRmaticatthefrontandrearaxleisafullysupportingsuspensionsystem.Itkeepsthevehiclelevelconstantwhentheengineisrunningirrespectiveoftheload.At
thesametimeairfromtheaircompressorisdeliveredtothespringstrutsviathevalveunituntilthevehiclelevelhasbeenadjusted.Thevehiclelevelatthefrontaxleis
recordedbytwolevelsensorsattherearaxleandconveyedtotheAIRmaticwithADScontrolmodule.Thelevelattheindividualspringstrutsiscontrolledbyfourlevel
valvesinthevalveunitandapressurereliefvalveontheAIRmaticcompressorunit.
AnAIRmaticcentralreservoirforcompressedairalsoenablesthevehicleleveltobecontrolledwhentheengineisnotrunning.Inadditiontheadjustmentofthevehicle
levelisdecoupledfromtheaircompressor.
Shutoffpositionfunction
Iftheunloadingofallthewheelswhenthevehicleisstationaryisrecognizedbythecontrolmodule,thespringstrutvalvesareclosed.Thevehiclethereforeremainsatthe
currentlevel.Thisisrequiredwhenchangingawheelorforrepairwork(hoist)forexample.
Normalfunction(enginerunning)
Whenthevehicleisstationarythelevelisreadjustedifthereisadifferenceofmorethan+/10mmafteradoororthetrunklidisopened.
Whiledrivingthelevelisreadjustedifthereisadifferenceofmorethan+/20mm.Thelevelisadjustedto+/10mmevery15minutes.
Dependingonthesituation,pressurecanbegeneratedbythecompressororthepressuresupplyoftheAIRmaticcentralreservoircanbeusedtoraisethevehicle.Whenthe
vehicleisstationarythepressurefromthereservoirisusedfornoisereasons.PressurecanalsobesuppliedfromthecompressorandAIRmaticcentralreservoiratthesame
timewhenthereisaparticularlyhighpressuredemand.
Theloweringofthevehiclelevelisrecognizedbythecontrolmodulefromthelevelsensorswhenloadingthevehicle.Byactuatingsolenoidvalvesairisdeliveredtothe
springstrutsoftheparticularfrontwheelorrearaxleuntilthevehiclehasreacheditsspecifiedvalue.Inadditionthepressurereliefvalveisopenedtoactuatetherespective
wheelvalvewhenunloadingthevehicle.
Wakeupfunction(operatingperiodapprox.1minute)
TheAIRmaticwithADScontrolmoduleis"wokenup"usingtheremotecontrol,doorcontactswitchesortrunkilluminationswitchinordertocheckthecurrentvehicle
levelforcriticalconditions(leveltoolow)andifnecessarytoraisethevehicleorloweritwhenunloading.Ifthevehiclelevelisloweredbymorethan30mm,itisraisedto
thenormallevelbythereservoir(onlywithareservoirpressure>11bar).Atavehiclelevelof<65mmandevenatareservoirpressureof<11baritisraisedoutofthe
"criticalrange"bythecompressorto63mm(condition:batteryvoltage>12.4V).
Ifthevehiclelevelisraisedbymorethan10mmwhenunloading,itisloweredtothenormallevelbyrelievingthepressure.
Thevehiclecannotberaisedbythelevelcontrolswitch.
Functioninvehiclecondition"IgnitionON"
Thesamefunctionasforthewakeupfunction,butwithouttimelimit.
Runonfunction(operatingperiodapprox.1minute)
After"ignitionOFF"thecontrolmoduleperformschangesinthelevelinordertobeabletoreadjustthevehiclelevel(raiseorlower)duringanyloadingorunloading
operations.(Thesamefunctionasforthewakeupfunction).
ComponentsAIRmatic
Locationofelectrical/electroniccomponentsAIRmatic:
A9/1AIRmaticcompressorunit
A1p13Multifunctiondisplay
B7AIRmaticpressuresensor
B22/3Rearaxlelevelsensor
B22/8Leftfrontlevelsensor
B22/9Rightfrontlevelsensor
B24/3Leftfrontbodyaccelerationsensor
B24/4Rightfrontbodyaccelerationsensor
B24/6Rightrearbodyaccelerationsensor
K40/7Rightfrontfuseandrelaymodule
kOAIRmaticcompressorrelay
N49Steeringanglesensor
N51AIRmaticwithADScontrolmodule
N72/1s2Levelcontrolswitch
N72/1s3Comfortandsportswitch
S9/1Stoplampswitch
X11/4Datalinkconnector
X11/4Datalinkconnector
Y36/6Levelcontrolvalveunit
Y51Leftfrontaxledampingvalveunit
Y52Rightfrontaxledampingvalveunit
Y53Leftrearaxledampingvalveunit
Y54Rightrearaxledampingvalveunit
Locationofpneumatic/hydrauliccomponentsAIRmatic:
40Frontspringstrut
41Rearspringstrut
42AIRmaticcentralreservoir
Y51Leftfrontaxledampingvalveunit
Y52Rightfrontaxledampingvalveunit
Y53Leftrearaxledampingvalveunit
Y54Rightrearaxledampingvalveunit
AIRmaticCompressorUnit(A9/1)
Theelectriccompressorgeneratesthepressurerequiredtoliftthevehicle.ThepressurereliefvalveintegratedintheAIRmaticCompressorUnit(A9/1)isusedtolowerthe
vehicle.
AIRmaticcompressorandvalveblockshownwith
bumperremoved.
m1Aircompressormotor
aAirfilter/cleaner
bOverpressure/residualpressurevalve
cAirdrier
gPressurereliefline
AIRmaticcompressorunit(A9/1).
DesignAIRmaticCompressorUnit
aAirfilter/cleaner
bOverpressure/residualpressurevalve
cAirdrier
gPressurereliefline
hMountingplate
ThemainpartoftheAIRmaticCompressorUnit(A9/1)isthecompressormotor(m1).Theotherpartsarethepressurereliefvalve,overpressure/residualpressurevalve(b)
andtheairdrier(c).
Theairfilter/cleaner(a)islocatedoutsidethecompressorunit.Itisconnectedtotheunitbyahose.Theairreleasedwhenthevehicleisloweredisreturnedtotheair
filter/cleanerviatheline(g)whereitisthenguidedbackoutthroughthefilter.
Thecompressorunitismountedtoamountingplate(h).
TheAIRmaticLevelControlValveUnit(Y36/6)isfixedatthetopofthesamemountingplateasthecompressorunitandisconnectedtothecompressorbyapressureline.
ThevalveunitisattachedtotheAIRmaticpressuresensor(B7).
FunctionAIRmaticCompressorUnit
m1Motorforaircompressor
y1PressurereliefvalveforAIRmatic
cAirdrier
dOutletvalve
EInletvalve
fPiston
Theaircompressorisdrivenbythecompressormotor(m1).Theairtobecompressedissuckedoutofthevehiclelongitudinalmemberthroughanairfilter/cleanerandinto
thechamberunderneaththepiston.Withthedownwardmovementofthepiston,theairpassesthroughtheinletvalve(e)inthepistoncrownintotheclearancevolume.
Withtheupwardmovementofthepiston,theinletvalveclosesandtheairiscompressed.Thecompressedairisforcedonviatheoutletvalve(d)intotheairdrier(c).
Thesilicatefillinginthedrierremovesmoisturefromtheair.Fromtheairdrierthedehumidifiedandcompressedairthenpassesfromtheairdrierintothecentralreservoir
ordirectlytothesuspensionstrutsasrequired.
Thepressurereliefvalveinstalledinthecompressorunit(y1)isrequiredfordischargingairwhenloweringthevehicle.Thedischargedairisconductedthroughtheair
filter/cleanerbackintotheatmosphere.Thisalsocleanstheairfilter/cleaner.
Theairdrierismaintenancefree.Themoistureisdeliveredbackintotheairwhenreducingthepressure.
AirFilter/CleanerAIRmatic
ItisdifficulttogetreliableinformationaboutthescheduledmaintenanceintervalontheAIRmaticairfilter/cleaner.W220communityrecommendstoreplacetheair
filter/cleanerfromtimetotimetopreventdamagetotheAIRmaticcompressor.Thefiltercanfillupwithdebrisandsaltwhichmayblocktheairfilter/cleaner.
Airfilters(newandold).
PartNumbersAIRmaticCompressorUnit
AIRmaticCompressorUnit
TheOEMpartnumbersareshownonthis2004AIRmaticCompressorUnit.
AirFilter/CleanerAIRmatic
TheAIRmaticCompressorAirFilter/Cleanerpartnumberis:A2203200069orA2203200069.
Somecatalogueslistitas"AirFilter,compressorintake."
AnewAIRmaticairfilter/cleanercostsaroundEUR10,anditshouldnottakemorethan20minutestoreplace.Forreplacementinstructionseecompressorreplacement
instructionbelow.
AirFilter/CleanerProtectiveBootAIRmatic
TheAirFilter/CleanerisprotectedwithaProtectiveBoot.(Note:ThearrowontheAirFilter/Cleanershowsthe'UP'directionandnotthedirectionofairflowwhichisboth
ways.)
TheAirFilter/CleanerProtectiveBootpartnumberis:A2203280279orA2203280279.
LevelControlValveUnit(Y36/6)AIRmatic
LocatedontheAIRmaticCompressorUnitintherightfrontfender,theLevelControlValveUnit(Y36/6)isthecentralcontrolunitforthelevelcontrol,leveladjustment
andsuspension.ItsuppliestheAIRmaticfrontandrearspringstruts(40,41)andtheAIRmaticCentralReservoir(42)withcompressedair.
TheLevelControlValveUnit(Y36/6)iscommonlyreferredtoasthe"ValveBlock".
A2203200258valveblock.
Y36/6Levelcontrolvalveunit. Y36/6Levelcontrolvalveunit.
Seealsosection"AirLineColourCodesLevelControlValveUnit(Y36/6)"below.
DesignAIRmaticLevelControlValveUnit(Y36/6)
TheAIRmaticLevelControlValveUnit(Y36/6)isattachedtothesameretainingplateastheAIRmaticCompressorUnit(A9/1).Ithasasolenoidvalveforeachwheel(y1,
y2,y3andy4)forraisingorloweringthevehicle.TheAIRmaticcentralreservoircharge(y5)isalsoinstalledinthevalveunit.TheAIRmaticpressuresensor(B7)is
locatedontheendfaceofthevalveunit.
6polyamidelinesleadfromtheAIRmaticLevelControlValveUnit
(Y36/6)tothesecomponentsconnectedatport:
1Leftfrontspringstrut
2Rightfrontspringstrut
3Leftrearspringstrut
4Rightrearspringstrut
PAircompressor
AirLineColourCodesLevelControlValveUnit(Y36/6)
AsseeninnextphotographGreen,Red,Yellow,Black,Blue,with'P'lineabovetheothers,Brown.
AirLineDesignationsLevelControlValveUnit(Y36/6)
FunctionAIRmaticLevelControlValveUnit
40Frontspringstrut
41Rearspringstrut
kResidualpressureholdingvalve
y1AIRmaticpressurereleasevalve
y1Leftfrontlevelcontrolvalve
y2Rightfrontlevelcontrolvalve
y3Leftrearlevelcontrolvalve
y4Rightrearlevelcontrolvalve
y5AIRmaticcentralreservoirchargevalve
aAircleaner
bPressurerelief/residualpressurevalve
cAirdrier
Forreasonsofsafetyonlyonevalveiseveractuatedatthesametime.Ifanaxleistoolow,cyclingtakesplacebetweentheleftandrightlevelvalve.
Raisingthevehicle
Thefrontleft,frontright,rearleftandrearrightlevelvalves(y1,y2,y3,y4)areopenedasrequiredandthecompressedairstoredinthecentralreservoirorgeneratedby
theaircompressormotorflowsfromthelevelcontrolvalveunit(Y36/6)totheindividualspringstruts.
Assoonastherequiredvehiclelevelisreachedatafrontwheel,therespectivelevelvalve(y1ory2)closes,theothervalvestillremainsopenuntilthesamevehiclelevel
hasalsobeenadjustedattheotherwheel.
Attherearaxlebothlevelcontrolvalves(y3andy4)closewhenthevehiclelevelaveragedbetweentherightandleftwheelcorrespondstothespecifiedlevelsetbythe
controlmodule.
Loweringthevehicle
Allthewheellevelcontrolvalves(y1,y2,y3andy4)areopeninthelevelcontrolvalveunit(Y36/6).
InadditiontheAIRmaticpressurereleasevalve(y1)intheAIRmaticcompressorunit(A9/1)isopenandthecompressedairisreducedviathisvalve.
Atthesametimethelevelvalvesoftheindividualwheelsremainopenuntilthedesiredvehiclelevelisreachedateachfrontwheelandattherearaxle.
PartNumberAIRmaticLevelControlValveUnit
TheOEMpartnumberisA2203200258or2203200258.
AIRmaticPressureSensor(B7)
TheAIRmaticPressureSensor(B7)islocatedintherightfrontfenderontheAIRmaticLevelControlValveUnit.Itmeasuresthesystempressureandisusedtocarryout
plausibilitychecks.
FunctionAIRmaticPressureSensor(B7)
aElectronicmodule(hybrid)
bFluidpressure
cLine
dMetalhousing
eGlassbody
fGlassinsulation
gReferencepressure
hPressuresensor
iSiliconeoil
kMetalprotectivediaphragm
Asensorelementcomparesthefluidpressure(b)tobemeasuredwithareferencepressure(g)inthesensor.Thepressure(b)istransmittedtotheactualsensorelement(h)
bymeansofametalprotectivediaphragm(k)andasiliconeoillayer(i).
Anelectronicsmodule(a)whichsuppliesthepressuresignalintheformofananalogvoltagetothecontrolmodule,islocatedonthemetalhousing(d).
LevelSensor(B22/3,B22/8,B22/9)
TheLevelSensor(1)functionistodetectthevehicleheightatthefrontaxleandrearaxleandsupplythevaluestotheAIRmaticwithADScontrolmodule.
TheLevelSensorworksbydetectingthevehicleheightusingalinkrodfromuppertransversecontrolarmatleftandrightfrontaxle.Asensorattherearaxlemonitorsthe
movementofthetorsionbaranddeterminestheaveragevehicleheight.
B22/8Leftfrontlevelsensor(Locationmirror B22/3Rearaxlelevelsensor.
imageforB22/9Rightfrontlevelsensor).
TheLevelSensorsconsistoftwoHallEffectsensorsinasinglehousingwhichproducetwosignals(redundantdesign).
Sensorfailureisdetectedbycomparingthetworedundantsignalsofeachsensor.
Sensorfailureisdetectedbycomparingthetworedundantsignalsofeachsensor.
LevelSensorIdentification
B22/3Rearaxlelevelsensor
B22/8Leftfrontlevelsensor
B22/9Rightfrontlevelsensor
PartNumberLevelSensor
A0105427617orA0105427617
AIRmaticCentralReservoir(42)
Metalcompressedairreservoir.Storescompressedairforlevelcontrol.Usedfordecouplingbetweencompressorandlevelcontrol.
42AIRmaticcentralreservoir.
AIRmaticcentralreservoirshownwithbumper
removed.
Comfortandsportswitch(N72/1s3)
ThisswitchcontrolsAdaptiveDampingSystem(ADS).
Theswitchwiththeindicatorlampsislocatedintheupperpartofthecenterconsole.
Dampingswitch(facelift). Dampingswitch(prefacelift). Levelanddampingswitch(producedupto08/99).
TheADSautomaticallyselectstheoptimumdampingfortherespectivedrivingconditions.Atthesametimethesuspensionissettoeithersportyorregular.
Thesuspensiontuningissetaccordingto:
Yourdrivingstyle
Roadsurfaceconditions
Yourchoiceofsuspensionstyle,"sport"or"convenience",whichyouselectusingthedampingswitch.
Thefollowingsuspensionstylesareavailable:
"Convenience"bothindicatorlamps(1)areoff.
"Sports1"oneindicatorlamp(1)ison.
"Sports2"bothindicatorlamps(1)areon(onvehiclesproducedafter09/99).
Theselectedsuspensionstyleisstoredinmemory,evenaftertheSmartKeyisremovedfromthestarterswitch.
Levelcontrolswitch(N72/1s2)
Levelcontrolswitch(facelift). Levelcontrolswitch(prefacelift).
ThisswitchcontrolsAirmaticLevelcontrolsystem.
Thefollowingvehiclelevelsettingscanbeselectedwhenthevehicleisstationary:
"Normal"fordrivingonnormalroads.Theindicatorlamp(1)isoff.
"Raised"fordrivingonroughroadsorwithsnowchains.Theindicatorlamp(1)ison.
Selectthe"Raised"levelsettingonlywhenrequiredbycurrentdrivingconditions.Otherwisethefuelconsumptionmayincreaseandhandlingmaybeimpaired.
Thevehiclechassisrideheightisraisedorloweredaccordingtotheselectedlevelsettingandtothevehiclespeed(theseheightadjustmentsaresosmallthatyoumaynot
noticeanychange):
Withincreasingspeed,rideheightisreducedbyuptoapproximately3/4in(20mm).
Withdecreasingspeed,therideheightisagainraisedtotheselectedvehiclelevel.
Theselectedvehiclelevelsettingremainsstoredinmemoryeveniftheengineisturnedoffandrestarted.However,thevehiclelowerstoregularlevelwhenyouexceeda
speedof75mph(120km/h)ormaintainaspeedofbetween50mph(80km/h)and75mph(120km/h)formorethan5minutes.
Thiscanbeusedtoraisethevehiclelevelby25mm(20mmUSA).Theraisedlevelswitchpositionisindicatedbytheredindicatorlamp(1)intheswitch.Inaddition,the
multifunctiondisplayintheinstrumentclusterdisplays:"AIRMATICVEHICLERISING".
"AIRMATICVEHICLERISING!"messageonthe
instrumentcluster(prefacelift).
Aslongasthemultifunctiondisplayintheinstrumentclustershowsthemessage:"AIRMATICVEHICLERISING",thedesiredvehiclelevelhasnotyetbeenreached.If
theraisingofthevehicleiscancelledduetothedrivingspeed,theinstrumentclusterdisplaysthefollowingmessageforapprox.10s:"AIRMATICLEVELSETTING
CANCELLED".Ifthevehicleisraisedseveraltimesinquicksuccession,itmayhappenthattheaircompressorshutsdowntemporarilyinordertopreventanoverload.The
raisingsequencewillthentakeanunusuallylongtime.
ControlModule(N51)AIRmaticwithADS
FunctionAIRmaticwithADSControlModule(N51)
ToexecuteallcontrolfunctionsofADSandAIRmatic.
LocationAIRmaticwithADSControlModule(N51)
AIRmaticwithADSControlModule(N51)islocatedinleftfusebox.
InputFunctionsAIRmaticwithADSControlModule(N51)
InputFunctionsAIRmaticwithADSControlModule(N51)
TheAIRmaticwithADSControlModule(N51)receivesinputsignalsoverCANBusfromthefollowingcomponents:
ESPcontrolmodule
Enginecontrolmodule
Transmissioncontrolmodule
Instrumentcluster
Steeringanglesensor
ADScomfortandsportswitch
Leveladjustmentswitch
Threebodyaccelerometers
Twofrontaxlelevelsensors
Onerearaxlelevelsensor
OneAirmaticpressuresensor
OutputFunctionsAIRmaticwithADSControlModule(N51)
TheinputsignalsareconvertedintheAIRmaticwithADSControlModule(N51)tooutputsignalsforthefollowingcomponents:
FourLevelcontrolvalves
Onemainreservoirchargevalve
FourADSdampervalves
Multifunctiondisplay
Switchindicatorlamps
Aircompressor
CompressorRelay(K40/7kO)AIRmatic
TheAirmaticCompressorRelay(K40/7kO)islocatedinrightfusebox,location'O'(thefirstonenexttothethree40ampfuses).
TherelaystartsandstopstheAirmaticcompressor.
Afaultyrelaymaycausethecompressortooverheatthusdamagingit.
Thefuse32nexttotherelayprotectstheAIRmaticcircuit.
Hellarelayshaveproventobereliable.Forpartnumbersee[1](https://w220.ee/Airmatic#Replacing_Relay_K40_7kO__Airmatic).
Airmaticfuse32.
Airmaticcompressorrelay.
AirSuspensionSpringStrut(40,41)AIRmatic
TheAirSuspensionSpringStruttakesoverallthefunctionsofsuspension,levelcontrol,leveladjustmentanddampingtobecarriedout.
40Frontaxlespringstrut. 41Rearaxlespringstrut.
DesignAirSuspensionSpringStruts(40,41)
Asingletubegasfilleddamperunitorshockabsorberisintegratedintotheairspringstrut.Aresidualpressurevalveisincorporatedintotheinletfittingonthetopofeach
airspringstrut.
40FrontaxleAirSuspensionSpringStrut
41RearaxleAirSuspensionSpringStrut
aStruttube
bCylindricaltube
cPistonrodgasket
dPistonrodguide
ePistonrod
fWorkingpiston
gReboundbufferspring
hAirbagorbladder
iStopbuffer
kResidualpressurevalve
lAirchamber
mDividingpiston
nProtectivebootorbellows
oGaspressurechamber
DesignFrontAxleSpringStrut(40)
TheFrontaxleairspringstrut(40)consistsofthreemainsystems:
Dustcoverandprotectivebootcalledabellows
Airspring(struttop,residualpressureholdingvalve(k),seals,airbag/bladder(h),struttube(a))
Gaspressurizeddamperorsingletubegasfilledshockabsorber.
Componentsoffrontaxlespringstrut.
ProtectiveBootorBellowsFrontAxleAirSpringStrut(40)
WISidentifiestheProtectiveBootastheBellowsfortheFrontAxleSpringStrut(40).Seeitem7inthenextfigure.
AirSpringPlungerandSupportBushingFrontAxleSpringStrut(40)
TheAirSpringPlungerisitem8inthenextfigure.Itistheconicalflaredlowerendoftheprotectivebootorbellows.
TheAirSpringPlungerfitsovertheSupportBushingwhichistheconicalseatoritem9ontheDamperUnitinthenextfigure.
OperationAirSpringStruts(40,41)
Whenfilledwithair,therubberairbagorbladder(h)rollsupanddownthealloylowersectionstruttube(a).
thestruttube(a)iscoveredbyaprotectivebootorbellows.
Withoutairandunderloadtheprotectivebootorbellowsisallowedtokinkandcreaseandtheairbagorbladderwouldalsohavethetoppressedhardintotheinside
oftheairchamber(l).
Theonlyslidingactionisinthestrutdamperunitwhichisoilfilledandgaspressurized.
FunctionAirSpringStruts(40,41)
Theweightofthevehicleiscarriedbythecompressibleair(l)sealedintotheairbagorbladderoftheairsprings.Therollingairbagorbladder(h)ismadeofrubber.Under
dynamicloadduringdriving,theairbagorbladder(h)rollsupparallelwiththeaxisofthespringstrut,thusprovidingthenecessaryspringtravel.Therollupzoneonthe
airspringstrutissealedofffromtheoutsidebyarubberprotectivebootorbellows(n)asaprotectionagainstdirt.
Thevehiclelevelisraised/loweredbyincreasing/reducingtheairpressureintheairchamber(l),whichresultsinalengthening/shorteningoftheairspringstrut(40).
ResidualPressureHoldingValve(k)
Eachairspringstrutincorporatesaresidualpressureholdingvalve(k)whichblocksofftheairspringpressurechamberfromthesupplylineintheeventofapressuredrop
atorbelowaresidualpressureof45bar.
PartNumbersAIRmaticAirSpringStruts(40,41)
OEMAIRmaticAirSpringStruts(40,41)
Front(without4MATIC):
A2203205113(replacedbyA2203202438)
A2203202438
Front(4MATIC):
Left:A2203202138
Right:A2203202238
Rear:
A2203205013
A2203207913(foroptioncodeZ04)
A2203207813(foroptioncodeZ07)(replacedbyA2203202338)
A2203202338(foroptioncodeZ07)
OE(Bilstein)AIRmaticAirSpringStruts(40,41)
SinceBilsteinisOEMmanufacturerforW220AirSpringStruts,itispossibletobuyOEstrutsdirectlyfromBilsteinmuchcheaper.Itispossibletopurchaseabrandnew
BilsteinstrutforaboutUS$700.
Frontleft(4Matic):44051518
Frontright(4Matic):44051525
Front:44042295
Rear:44042301
ArnottAIRmaticAirSpringStruts(40,41)
ArnottsellsbothnewandremanufacturedAIRmaticAirSuspensionStrut.Itispossibletoget10%discount[2](http://www.benzworld.org/forums/arnottinc/2152737
arnottairsuspensiondiscountcodestill.html)whenmakinganorderonline.
Arnottclaims[3](http://www.benzworld.org/forums/arnottinc/1508879airmaticfailurepicturesdetails.html)thattheirproductsuseanimproveddoublethicknessair
springbag/bladdermanufacturedbyContinentalwhichprovideslongerlifetimethantheOE.
Infact,Arnottprovideslimitedlifetimewarranty[4](https://www.arnotteurope.com/images/Arnott%20Europe%20Warranty%20Info%202015.pdf)fortheirAIRmaticAir
SuspensionStruts.
ArnottRemanufactured.AnArnottremanufacturedAIRmaticAirSuspensionStrutcostsaboutUS$575butnoteitonlyhasinstallednewrubberairbags/bladders
andnottheshockpistonsealsorgascharge.
ArnottNew.ArnottnewAirSpringStrutscostaboutUS$624.
NotewithallnewArnottAIRmaticAirSuspensionStrutsyoulosetheelectronicdamping.WhilethenewArnottAIRmaticAirSuspensionStrutsallowyoutopluginthe
originalwireharnessfromthecar,itsimplyfoolstheAIRmaticcomputerintothinkingtheselectivedampingisfunctioning.Inrealityit'snotandtheshockhasconstant
dampingsettingcorrespondingtoOE"comfort/convenience"setting("sport1"and"sport2"dampingsettingsarenotavailable).
AdaptiveDampingSystem(ADSII)AIRmatic
FunctionAdaptiveDampingSystem(ADSII)
TheAdaptiveDampingSystem(ADSII)viatheDampingValveUnit(Y51,Y52,Y53,Y54)adaptsthedampingforcetothedrivingstyleandroadcondition.Thedamping
forceisregulatedindampingvalves(Y51,Y52,Y53,Y54).Eachwheelhasonedampingvalveinstalledbetweentheupperandlowerchambersofthesinglepipegasfilled
shockabsorber.
Eachdampingvalvecontainstwoelectromagneticvalves(y1,y2),allowingfourdifferentdampingforcesettingsaccordingtohowtheyareactuatedviatheAIRmaticwith
ADScontrolmodule.
Theextremelyshortadjustingtime(milliseconds)meansthattheoptimumdampingforcesettingisavailablealmostimmediatelyifsuddenchangesinthevehiclelevelare
required,suchasduringanobstacleavoidancemaneuver.
Y53Leftrearaxledampingvalve.
Y53Leftrearaxledampervalve(mirrorimage Y51Leftfrontaxledampervalve(mirrorimage
forY54). forY52).
DesignDampingValveUnit(Y51,Y52,Y53,Y54)
Y51leftfrontaxledampingvalve
y1frontaxlesolenoidvalve1
y2frontaxlesolenoidvalve2
ppistonreedvalvepack
TheDampingValveUnit(Y51,Y52,Y53,Y54)consistsofacasingand2pistonreedvalvepacks(p).Locatedabovearethespringloadedsolenoidvalvepistonsandthe
solenoids.Thevalvepistonsandsolenoidsformthesolenoidvalveunits(y1,y2).
Ifthesolenoidvalvecoils(y1,y2)arenotactuated,thespringloadedsolenoidvalvepistons(y1,y2)keeptheholesdirectlybelowthemclosed.Oilisdisplacedviathereed
valvepacks(p)andtheoilductlocateddiagonallyoppositeinthecasing.
Ifthesolenoidvalvecoil(y1)isactuated,forexample,thesolenoidvalvepiston(y1)allowstheholetoopenandtheoilcanflowoverthishole.Onlyasmallamountofoil
isdisplacedviathepistonreedvalvepack(p).Thedampingforcelevelsareachievedbymeansofthedifferentlypositionedreedvalvepacksandcontrollingthesolenoid
valves.
ComponentsDampingValveUnit(Y51,Y52,Y53,Y54)
40Frontaxleairsuspensionstrut
40Frontaxleairsuspensionstrut
Y51Dampingvalve
y1Solenoidvalve1
y2Solenoidvalve2
aBypassvalve,hardcompression
bBypassvalve,softrebound
cBypassvalve,hardrebound
dBypassvalve,softcompression
fOperatingpiston
mDividingpiston
oPressurechamber
rBottomvalve
Illustrationshowsfrontaxlesuspensionstrutand
associatedDampingValveUnit.Thereedvalves(a,
b,c,d)consistofaballvalveandthrottle.
ForceSettingsAdaptiveDampingSystem(ADSII)
TheADSsuspensioncontrolmoduleisusedtoachievefourdifferentdampingforcesettings:
Dampingforcesetting1
Forcomfortablerollingwithsmallsprungmassvibrationsandlowlongitudinalandlateralacceleration.Withthisdampingforcesettingbothsolenoidvalvesy1and
y2areopensothatmostoftheoilflowsparalleltothehardreboundandcompressionoftheoperatingpistonviathesofterreedvalvesatthesolenoidvalves.The
comfortreboundandcompressionsettingisthereforeachieved.
Thereedvalvesatthevalvepistongenerateafirmersetting.Ifthevehicleislowered,solenoidvalvey2isopenedandsolenoidvalvey1isclosed.Thereedvalves(a
=hardcompressionandb=softrebound)atsolenoidvalvey1generateahardcompressionandasoftrebound.
Thereedvalvesatthevalvepistongenerateanevenfirmersetting.Ifthevehicleisraised,solenoidvalvey1isopenedandsolenoidvalvey2isclosed.Thereed
valves(c=hardreboundandb=softcompression)atsolenoidvalvey2generateahardreboundandasoftcompression.
Dampingforcesetting4(drivingsafetysetting)
Forincreaseddrivingsafetywithhighlongitudinalandlateralvehicleacceleration.Bothsolenoidvalvesy1andy2areclosed.Thereedvalves(a=hardcompression
andc=hardrebound)generateahardcompressionandrebound.Alltheoilflowsviathehardreboundandcompressionoftheoperatingpiston.Thisdampingforce
settingisalsoselectediftheADSsystemfailsandtheADSsuspensionwarninglight(A1e27)comesonintheinstrumentcluster.
Switchingfordampingforcesettings
Dampingvalves(Y51Y54) Valvecontrol
Dampingforcesetting
Rebound Compression Solenoidvalve(y1) Solenoidvalve(y2)
1 Comfort Comfort Open Open
2 Soft Hard Closed Open
3 Hard Soft Open Closed
4 Hard Hard Closed Closed
Multifunctiondisplay(A1p13)
VariousmessagesconcerningtheAIRmaticandADSareshowninthemultifunctiondisplayintheinstrumentclusterandinthecomfortandsportandleveladjustment
switches.
AIRMATICVISITWORKSHOP!
IntheeventofelectricalfaultsintheAIRmaticorADSsystem,thefollowingmessageappearsonthemultifunctiondisplayintheinstrumentcluster:"AIRMATICVISIT
WORKSHOP!".
ThefaultisstoredintheADSsuspensioncontrolmoduleandcanbereadoutusingthediagnosistool.
"AIRMATICVISITWORKSHOP!"warningon "AIRMATICVISITWORKSHOP!"warningon
theinstrumentcluster(prefacelift). theinstrumentcluster(facelift).
LimphomeFunction
AmalfunctionintheadaptivedampingsystemcausestheADStoshutdown.Thesuspensionisswitchedtothehardestsetting.Intheeventofafaultinthesuspension
systemorintheleveladjustmentsystem,thevehicleattemptstomaintainthesetlevel.Manualandautomaticleveladjustmentsarenolongerpossible.
AIRMATICSTOP,CARTOOLOW!
Ifthevehiclelevelatthefrontaxleismorethan50mm(60mmUSA),orattherearaxlemorethan60mm(70mmUSA)belowthenormallevel,themultifunctiondisplay
intheinstrumentclusterdisplaysthewarning:"AIRMATICSTOP,CARTOOLOW!".
"AIRMATICSTOP,CARTOOLOW!"warningon
theinstrumentcluster.
Thedisplaydisappearsagainwhenthelevelhasrisenbackto48mmor58mm(58mmor68mmUSA)respectivelybelowthenormallevel.
IssuesandTroubleshootingAIRmatic
Note:IftheAIRmaticleakssubstantiallyitisimperativethatitbefixedassoonaspossibleorelsetheAIRmaticpumpmayburnout.Iftheleakcannotbefixed
immediatelyremovetheAIRmaticcompressorrelay(K40/7kO)todisabletheAIRmaticPump.Fortherelayandfuselocationscontrolclickforanewtabhere[5]
(https://w220.ee/Airmatic#Compressor_Relay_.28K40.2F7kO.29__AIRmatic).HoweverBEWARNED,thevehiclemayleakenoughtobenotdrivablewhenturningthe
frontwheelscausesthemtotouchthetopofthewheelarch.
"AIRMATICVISITWORKSHOP!"messageontheinstrumentcluster
"AIRMATICVISITWORKSHOP!"warningon
theinstrumentcluster.
ThismessageisshownintheeventofelectricalfaultsintheAIRmaticorADSsystem.UseDAStoreaderrorcodes.
Error
Description Probablecause
Code
Couldbecausedbyfaultysolenoidvalveinthestrutinwhichcasethestrutorstrut'sdampingvalveunit
shouldbereplaced.
FaultincomponentY53y1(Leftrearsolenoidvalve
C1324
1)inassemblyY53(leftrearaxledampingvalve Iftheerrorcodecomesinpairwithsecondselenoidvalveofthestrutthentheproblemisverylikelyinthe
001
unit) connection.ChecktheelectronicconnectionbetweenthestrutandAIRmaticwithADScontrolmodule
(N51).
FaultincomponentY53y2(Leftrearsolenoidvalve
C1325
2)inassemblyY53(leftrearaxledampingvalve Seeabove.
001
unit)
"AIRMATICSTOP,CARTOOLOW!"messageontheinstrumentcluster
"AIRMATICSTOP,CARTOOLOW!"warningon Airmaticstrutwithtoolowpressureresultingin
theinstrumentcluster. vehicleheightbeingtoolow.
VehicleLevelTooLow
Mostcommonreasonforacarbeingtoolowisaleakingstrut.Note:thestrutitselfhasaresidualpressureholdingvalvewhichisdesignedtostopairescapingoutofthe
Mostcommonreasonforacarbeingtoolowisaleakingstrut.Note:thestrutitselfhasaresidualpressureholdingvalvewhichisdesignedtostopairescapingoutofthe
strutoncetheinternalpressuredropsbelowaresidualpressureof45bar.
AirBag/BladderLeaking
UsuallythethemostcommonsourceofaleakingstrutisafailedrubberAirBag/Bladder(h).
FailureiscausedbytheAirSpringAirBag/Bladder(h)chafingagainsttheprotectivealloydustcoverovertime.TheoriginalAirBag/Bladder(h)ismadefromaverythin
singlenyloncordlayer,andverticalweakspotsorlineswilldevelopandeventuallypopthrough,causingacompletefailure.
UnliketheOEAirBag/Bladder,remanufacturedonesusuallyusetwoplyrubberdesignthatpreventsverticalwearpointsandtheAirBag/Bladderisusuallyovertwo
timesthickerthantheoriginalone.
ItispossibletoreplaceadamagedAirBag/Bladder(h),however,therubberAirBag/Bladderisattachedtothestruttubeandstruttopwithcrimprings.Thisrequiresaccess
toanhydrauliccrimper,whichisnoteasilyavailableforaDIYer.
Fortunately,itispossibletopurchaseoneBayarefurbishedAirSpringwhichisthetoppartofanairsuspensionstrutforaroundEUR120andmountittotheoriginal
damperunit(thelowerpartofanairsuspensionstrut).
AirSpringofthefrontstrut. AirSpringoftherearstrut.
ThisrequirestheStruttoberemovedfromthecarandtheAirSpringtobeseparatedfromtheDamperunitbypartlydismantlingtheAirSpring.FortheDIYProcedure
controlclickforanewtabhere[6](https://w220.ee/Airmatic#Replacing_the_Air_Spring_in_an_AIRmatic_Strut).
Note:thesamesymptomsasaleakingstrutcanbeobservedifthelinetothestrutisfaultyorthevalveblockisfaulty(controlclickforanewtabhere[7]
(https://w220.ee/Airmatic#Level_Control_Valve_Unit_Leaking)),sobesuretoeliminatethesecausesbeforereplacingastrut.
Iftheleakissevere,ahissingsoundcanbeheardfromthewheelhousearea.
Afaultystrutcanoftenbelocatedvisuallybyobservingtherelativeheightsofeachcornerofthevehicle,butbeawarethatitisverylikelythatthewheelontheotherside
(orthewheelonotheraxleonthesameside)willalsobebroughtdownsignificantly,butusuallytoasmallerextent.
Tobethorough,anobjectivetestisbestperformed.
Ensurethevehicleisparkedonalevelsurface.
Measuretheheightateachcornerofthevehicleandrecordtheresults.
HeightMeasuringTechnique
UseatapemeasuretomeasurefromunderneaththeedgeofawheelarchtothecentreoftheMBStarLogointhewheelhubcap.Thistechniqueremovesvariationscaused
bytyrepressures.
SampleResultsfora2003W220S500LwithnoAIRmaticleaks.
Donotdisturbthevehiclefor10hours.(Ensurethecarremains"asleep"duringthistime.)
Remeasuretheheightateachwheelandrecordtheresults.
Calculatethedropateachwheelandcomparewiththespecification.
LeakageSpecification
MBDASstatesthedropinvehicleheightmustbelessthan20mm(30mminverycoldconditions)in10hours,ielessthan2mmperhourisallowed.
TopSealsLeaking
Thesealsatthetopsofthefrontsuspensionstrutsdevelopleaks.Thisissuewasmorecommonwiththeolderdesigninthepre'03ishW220'scomparedtothosefromafew
yearslater.Thereisavailableanepoxyrepairkitthatcanbeusedtoclosethecracks.AprofessionalrepaircostsaroundUS$550partsandlaborforbothsides.
NotethenewerW220'spost'03andoneswhichhavebeenmodifiedwithnewreplacementpartsdonotleakatthetopsealwhichisan'O'ringaroundthemetalcover
disc.Thetopoftheairsuspensionstrutontheselatermodelsisfilledwithabutylmasticcompoundtoreducevibrationontheresidualvalveinletconnection.
RepairOptionsAIRmaticAirSuspensionStrut
IfanyAIRmaticAirSuspensionStruts,Frontaxle(40)orRearaxle(41)needcompletereplacement,controlclicktoopenanewtabhere[8]
(https://w220.ee/Airmatic#Part_Numbers__AIRmatic_Air_Spring_Struts_.2840.2C_41.29)forthepartnumbersandreplacementoptions.
FortheDIYProcedurescontrolclicktoopenanewtabhere[9](https://w220.ee/Airmatic#Replacing_Front_Axle_Spring_Strut_.2840.29__AIRmatic).
ReplacementAIRmaticFrontAxleandRearAxleAirSpringsarealsoavailableandcanbeinstalledwiththeoriginaldampingunit.Controlclicktoopenanewtabhere
[10](https://w220.ee/Airmatic#Replacing_the_Air_Spring_in_an_AIRmatic_Strut)fortheDIYProceduresSection.
AIRmaticCompressorUnitFailure
AIRmaticCompressorUnit(A9/1)failureorpartialfailure.Totestthishypothesisstartthecarandseeifcompressorisrunning(youshouldhearcompressorinthefront
rightfenderrunning).
IfitisnotrunningcheckAIRmaticFuseandrelay(controlclicktoopenanewtabhere[11](https://w220.ee/Airmatic#Compressor_Relay_.28K40.2F7kO.29_
_AIRmatic)).Afaultyrelaymaycausecompressortorunnonstopwhichwillcausecompressortooverheatandblowoutthefuse.
PressureLinesLeaking
ThehighpressurelinefromtheAIRmaticCompressorUnit(A9/1)totheAIRmaticLevelControlValveUnit(Y36/6)developsaleak.Inthiscasereplacementlineora
repairjoinercanbeused.Controlclicktoopenanewtabhere[12](https://w220.ee/Airmatic#Line_Repair__AIRmatic)forthepartnumbers.
Itispossiblethatthepressurelinetothestrutdevelopscracksormicrocracks.
Incaseoffrontstrutsthelinefromvalveblocktostrutcanbetestedwithspraytest.
However,incaseofrearstrutsthelinegoesfromthevalveblocktorearthroughinteriorandthusisnotreachable.Asimpletestistorunanalternativelinefromthevalve
blocktothestruttocheckiftheoriginallineisfaulty(Controlclicktoopenanewtabhere[13](https://w220.ee/Airmatic#Line_Repair__AIRmatic)toseethesectionon
thelinerepair).
Ifthecrackislargeitmaysufficetopushairinthelineandlocatedamagedpointbyhearinghissingsound.
LevelControlValveUnitLeaking
TheAIRmaticLevelControlValveUnit(Y36/6)orValveBlockontopoftheAIRmaticCompressorUnit(A9/1)fails(verycommon)andfailstoclosesomevalve.
Inthiscasethepressurewillbereleasedbacktoaircompressorandoutofthesystem.
Forhowtoinspectvalveblockforleaks,controlclicktoopenanewtabhere[14]
(https://w220.ee/Airmatic#Inspecting_level_control_valve_unit_.28Y36.2F6.29_for_leaks)toseesection"Inspectinglevelcontrolvalveunit(Y36/6)forleaks".
Usually,incaseofvalveblockleakthevehiclewillnotbecompletelydown,sincetheresidualpressureholdingvalveattheairinlettothestrutswillpreventthepressure
droppingbelowapressureof45bar.
Vehiclelowduetovalveblockleak.
CentralReservoirLeaking
TotestwhethercentralreservoircankeeppressureDAScanbeusedwhichhasapressuretestforreservoir.
Iftestshowsthatreservoircannotkeepthepressure,beforereplacingit,checkwithspraytotestifthelinetoreservoirisfaulty.
LevelSensorFaulty
Therearetwolevelsensors(B22/3,B22/8)foreachfrontwheelandonefortherearaxle(B22/9).
Ifthelevelsensorreportswrongheightthesystemwillthinkthatvehiclealreadyhastherequiredlevelandwillnotraisethevehicle.
InformationreportedbylevelsensorscanbeviewedusingDAS.
Ifthevehiclerises,butthenfallsdownagain,thelevelsensorsarelikelynotthecause.
VehicleLevelTooHigh
W220withtoohighrear.
LevelControlValveUnitLeakingVehicleTooHigh
ItispossiblethatLevelControlValveUnit(Y36/6)failstoclosesomevalveinwhichcasethepressurewillbereleasedbacktostrutraisingthecartoohigh.
Thevehicleishighonlywhilethecarisoff,sinceassoonasvehicleisstartedthecomputerwilltrytoadjusttheleveltotheprogrammedlevel.
LevelSensorFailure
Therearetwolevelsensorsforeachfrontwheelandonefortherearaxle.
Ifthelevelsensorreportswrongheightthesystemwillthinkthatvehiclelevelistoolowandwillrisethevehicleabovenormalheight.
InformationreportedbylevelsensorscanbeviewedusingDAS.
ValveFailureRearSuspensionStrut
OftentheVehicleLevelTooHighproblemliesinbadelectricalconnectionbetweentherearstrutandAIRmaticcontrolmodule.
ProtectiveBoot/BellowsFailure
OnolderandhighermileagevehiclesthelowerdustcoveronanAIRmaticairsuspensionstrutstartstowearandfail.Thisplasticprotectiveboot/bellowsisdesignedto
preventdirtandcontaminationgettingtotheairspringbag/bladder.Afteraround100,000miles(130,000Kms)theyoftenshowsignsofcrackingandtearing.Failureto
replacemeanstheendisnearforthewholestrut.
UpperMountRubberBushFailure
AbumpingorknockingnoisecomingfromthetopofthefrontsuspensionmayindicateawornuppermountrubberbushingintheAirSpring.
WhentheAirSpringsweremanufacturedtheuppermountrubberbushingswereinstalledcompressed.Asthemountsweakenwithagetheycanlosetheircompressionand
causeabumpingsound.
ThenextimageshowsatypicalwornuppermountrubberbushingremovedfromanAIRmaticairsuspensionstrutwitharound80,000to100,000miles(130,000KMto
161,000Km).Awornmountwillalsocontributetomanyunwantedproblemswithyourairsuspension.
PartNumberUpperMountRubberBush
ThepartnumberforaFrontStrutuppermountingrubberbushfora2003updateW220S500LisA2203200273or2203200273.
ItappearsfrominspectionoftheexplodeddiagramsfortheAIRmaticfrontandrearstrutsthattheuppermountrubberbushmaybeidenticalforthefrontandrearstruts.
NOTEThisisyettobeconfirmed.
EmergencyProcedureAIRmatic
Incaseof"AIRMATICSTOP,CARTOOLOW!"warningontheinstrumentcluster,thevehicleshouldbestoppedimmediatelyandmeasurestaken.
Possibleconsequencesofridingwithleakystrut:
Thecompressorwillrunendlesslywhichmaycausecompressorburnout.
Ifthefrontislow,thetirewillrubtheinnerfender.
Thereisariskofdamagingotherstrutonthesameaxis.
Thereisatemporaryfixforfrontstruts,whichcanbeusedtogettotheclosestworkshop:
Step1:Buywoodenblocksandcableties Step2:Jackupthecaralittle.
Step3:Insertwoodenblockandfixitwithcable Step4:Lowerthecar.
ties.
Theridewillbelittlebumpy,butnotmuchharsherthanitiswhenpushingthebuttonthatstiffensthesuspension.
Originallimphomebuffers
1bRearaxlelimphomebuffers
77Torsionbar
1aFrontaxlelimphomebuffers
6Uppertrackcontrolarm
Frontaxle
MountlimphomebufferA2203271230(1a)ontouppertransversecontrolarm(6).Slowlylowervehicleandmakesurethatthelimphomebuffermakescontactwithtopof
wheelhouse.
Rearaxle
SlidelimphomebufferA2203280839(1b)inbetweenbodyfoldandtorsionbar(77).Thebodyfoldmustlieinthegrooveofthelimphomebuffer.Slowlylowervehicle
andmakesurethatthetorsionbar(77)makescontactwiththelimphomebuffer(1b).
TipsAIRmatic
DepressuriseAIRmaticcomponents(suspensionstruts,valveunit,reservoirunit)beforeremovalusingSTARDiagnosis.WISstatesthatcomponentsortheentire
systemmustNOTbedischargedbyunscrewingpressurelineconnectorsalthoughmostDIYershavedonethiswithoutproblems.Justbesuretoopenanypressure
lineconnectionsslowlytoavoidasuddenlossofpressure.
Soiledpressurelineconnectorsmustbecleanedbeforeunscrewing.
MarktheLevelControlValveUnit(Y36/6)withthecoloursoftheairlinesBEFOREremovingthemtoavoidhavingtoprintouttheguideinsection"AirLine
ColourCodesLevelControlValveUnit(Y36/6)"below.[15](https://w220.ee/Airmatic#Air_Line_Colour_Codes__Level_Control_Valve_Unit_.28Y36.2F6.29).
Sealofftheexposedpressurelineportsimmediatelywithblindplugsifpossible.Apieceofmaskingtapeovertheholesisashorttermsolution.
Sealoffthepressurelinesimmediatelytokeepcleanbyplacingtheexposedendsinsmallplasticbagssealedwithtape.
WISstatesyoumustonlyuseflarenutwrenchesorspecialtoolstounscrewthepressurelines,howevermostDIYershaveused10mmopenendedspanners
successfully.Justbecarefultonotroundthehexhead.
Replacingonestutatatimeispossibleaslongasthevalveblockhasnoproblems.Thevalveblockhasavalveforeachstrutsupplypipeandifthevalvesremain
closedthennoairwillleakfromtheotherstrutswhilstonestrutisoff.ButBeWarned,ifthevalveblockisfaultythenanyofthestrutscouldlooseairafterreleasing
thesupplylinefromastrut.
TheAllenheadStubScrewsholdingthebottomofthefrontstrutuseLoctitethreadfastenersoalittleheatfromagastorchalwaysdoesthetrickinbreakingthe
sealant.
DonotfullyremovetheStubScrew,justunscrewthemsothataboutfivethreadsareshowing.Itisveryeasytodamagethethreadswhenreinstalling.
1.
Whenreinstallingastrutensurethattheplugattheelectricalconnectionispressedhomefirmly.TIP:Iftheplugandsockethavebeencleanedwellyoushouldhear
anaudible'click'whentheconnectorisfullyhome.
DIYRepairsAIRmatic
BeforeattemptinganyDIYrepairsmakesuretoreadthe"TipsAIRmatic"section.Controlclickheretoopeninanewtab[16](https://w220.ee/Airmatic#Tips_
_AIRmatic).
ReplacingRelayK40/7kOAIRmatic
TheOEMrelayswereHellarelays.PartnumberAR400779113(MBA0025427219or0025427219).
InspectingAIRmaticLevelControlValveUnit(Y36/6)forleaks
GeneralleaktestingLevelControlValveUnit(Y36/6)
LeakTestingUsingSDS
STARDiagnosisSystem(SDS)offersaneasyandthoroughmethodfortestingtheAIRmatic.
UsingSDSnavigatetoAIRmaticPneumaticTests.
Thefollowingtestsareavailable
A9/1CompressorTest
Y36/6y1LeftFrontStrutTest
Y36/6y2RightFrontStrutTest
Y36/6y3LeftRearStrutTest
Y36/6y4RightRearStrutTest
A9/1y1PressureReliefValveTest
Leaktestbetweencompressorandvalveblock(LevelControlValveUnit(Y36/6)),iethe'P'valveandline).
Leaktestbetweenvalveblockandsuspensionstruts.
Leaktestbetweenvalveblockandcentralreservoir.
Asanexamplethislasttestdoesthefollowing
Centralreservoirchargevalve(invalveblock)isopened.
'P'(invalveblock)valveisopened.
Allothervalves(invalveblock)areclosed.
Compressoristurnedonfor<60secs.
Compressoristurnedoff.
'P'valve(invalveblock)isclosed.
Centralreservoirpressureismonitoredforleakagefor120secs.
TheCentralreservoirpressuremustnotdropbymorethan0.5barinthattime.
SampleResultsofLeakTestingUsingSDS
1.Leaktestbetweencompressorandvalveblock(LevelControlValveUnit(Y36/6)),iethe'P'valveandline).
Asanexamplethefollowingresultwasobtainedforaleaktestofthe'P'valveandlineforaFAULTYLevelControlValveUnit(Y36/6)orValveBlock.Thisissimilarto
the"bubbles"testshownbelow.
Afterallvalveblockvalveswereclosedthecompressorproduced10.56barwithin10secswhichisINSIDEthespecificationof10barwithin40secs.
Afterthecompressorwasturnedofftheinitialcompressorpressure('P'line)=10.56bar.
Afterthe120elapsedtimethefinalcompressorpressure('P'line)=5.30bar.
Thusthemeasuredleakageratewas5.26barin120secswhichisOUTSIDEthespecified0.5barin120secs.
SDSreportedthattherewasaleakageinthe'P'valveorthehighpressurelinebetweenthecompressorandthevalveblock.
Asquirtofsomesoapysolutiononthehighpressurelinebetweenthecompressorandthevalveblockprovedthatthelineanditsassociatedconnectorswerenotleaking.
Thusthefaultwasaleakyinternal'P'valveinthevalveblock.Oncethe'P'valveconnectorwasremovedfromthevalveblock,asimpletestbyapplyingasoapyfingerover
theportproducedobviouspositivepressureofairescapingfromtheport,thusconfirmingthediagnosisofaleakyinternal'P'valveinthevalveblock.
UnfortunatelythevalveblockcannotbedismantledforinspectionandcleaningandanewLevelControlValveUnit(Y36/6)wasrequired.
Asacomparison,afterreplacingtheLevelControlValveUnit(Y36/6)orValveBlockwithaBRANDNEWOEMpart,thefollowingresultwasobtainedforaleaktestof
the'P'valveandline.
Afterallvalveblockvalveswereclosedthecompressorproduced10.8431barwithin10secswhichiswithingthespecificationof10barwithin40secs.
Afterthecompressorwasturnedofftheinitialcompressorpressure('P'line)=10.8431bar.
Afterthe120elapsedtimethefinalcompressorpressure('P'line)=10.8431bar.
Thusthemeasuredleakageratewas0.0barin120secswhichisINSIDEthespecified0.5barin120secs.
Thusthemeasuredleakageratewas0.0barin120secswhichisINSIDEthespecified0.5barin120secs.
2.Leaktestbetweenvalveblockandcentralreservoir.
Asanotherexamplethefollowingresultwasobtainedforaleaktestbetweenvalveblock(LevelControlValveUnit(Y36/6))andcentralreservoirforaFAULTYLevel
ControlValveUnit(Y36/6)orValveBlock.
InitialCentralReservoirpressure=12.07barreachedin60secs.
AfterCompressorturnedofftheCentralReservoirpressure=10.84bar.
After120secselapsedtimetheCentralReservoirpressure=10.57bar.
Conclusion:ThisrealworldCentralReservoiranditsassociatedsupplylineafter220,000Kmproducedaleakagerateof0.27barin120secs,whichiswellwithinthe
specified0.5barin120secs.
Asacomparison,afterreplacingtheLevelControlValveUnit(Y36/6)orValveBlockwithaBRANDNEWOEMpart,thefollowingresultwasobtainedforaleaktest
betweenvalveblock(LevelControlValveUnit(Y36/6))andcentralreservoir.
InitialCentralReservoirpressure=7.549barreachedin60secs.
AfterCompressorturnedofftheCentralReservoirpressure=7.41177bar.
After120secselapsedtimetheCentralReservoirpressure=7.41177bar.
Conclusion:ThisrealworldCentralReservoiranditsassociatedsupplylinetoabrandnewLevelControlValveUnit(Y36/6)orValveBlockproducedaleakagerate
of0.0barin120secs,whichiswellwithinthespecified0.5barin120secs.
LeakTestingWithoutSTAR
Here'showtodoageneralleaktest.
1.Ontherighthandsideofthevehicleremovepartofthewheelhouseinnerpanelinfrontfender.
2.Spraythepressurelineconnections1,2,3,4,5,Pofthelevelcontrolvalvewithleakdetectingspray.
3.Inspectforanindicationofleaking.Severeleaksareevidentimmediately.
4.Waitforapprox.1015minutesaftersprayingandreinspect.Thismeansthatminorleakscanberecognized(formingawhitecap).
TestforinternalleakLevelControlValveUnit(Y36/6)
Commonfailuremodeofthelevelcontrolvalveunit(Y36/6)iswhensomevalvesfailtoclosethusreleasingtheairoutofsystemthroughthePvalveorthroughother
valvesbacktostruts.
Here'showtodoatestforaninternalleak.
1.Ontherighthandsideofthevehicleremovepartofthewheelhouseinnerpanelinfrontfender.
2.TestwhetherthePvalveallowsairtorelease.
3.DetachthePlineconnectionattheaircompressorendandsprayitwithleakdetectionsprayorimmersetheendinasoapysolution.
4.Afterthetestusecompressedairtocleanthevalve.
ReplacingCompressorUnitAIRmatic
ObservethelocationoftheelectricalandpneumaticconnectionpointsontheAIRmaticCompressorUnit.
1Pressurelineconnection
2Intakehosewithairfilter
3Connectorforaircompressormotor
A9/1y1AIRmaticpressurereductionvalve
1.IfpossibledepressurisetheAIRmaticsystemusingSTARDAS.
2.Disconnectbattery.
3.Removeenginecompartmentpaneling(rightfrontpartonly).
4.Unscrewpressurelineconnection(1)fromAIRmaticcompressorunit(A9/1).
5.DetachconnectoronAIRmaticpressurereductionvalve(A9/1y1).
6.Disconnectconnectorforaircompressormotor(3).
7.Pullintakehosewithairfilter(2)outoflongitudinalmember.
8.IftheAIRmaticairfilter(2)isreplaced,thearrowontheairfilter(2)mustpointupwards.ForthepartnumberfortheAIRmaticAirFiltercontrolclicktoopena
newtabhere[17](https://w220.ee/Airmatic#Air_Filter.2FCleaner__AIRmatic_2).
9.Unscrewnuts(arrows)andremoveAIRmaticcompressorunit(A9/1).
10.Detachaircompressorrelay(K40/7kO).Onlywheninstallinganewaircompressor.Whenreplacingtheaircompressortheaircompressorrelay(K40/7kO)should
alwaysbeexchangedastheswitchingcontactsmaybedamaged.
11.Installinthereverseorder.

1999-2006 Mercedes-Ben...
Airmaticcompressorreplacement(byArnott).
LineRepairAIRmatic
TheleakmayalsodevelopinanyofAirmaticpneumaticlines.
Thelinestotherearstrutsgothroughtheinterioranditisdifficulttofindtheleakunlessthecrackislargeenoughsothatthecrackcanbelocatedthankstoloudhissing
sound.Alternativelinecanberunfromfrontvalveblocktothereartotestifthelineisfaulty.
Alternativelinerunningtotherear. Alternativelineconnectedtotherearstrut.
Repairsectionofairline(A2203271045).Price Airlinerepairconnector(A0003270169).Price 4mm"pushin"pneumaticfitting.Alternativeto

EUR14. EUR45. A0003270169.PriceEUR3.
MBsellstheairline(pipe/hose)in5ftlengths,maximum.Fromthefactoryairlineisbuiltwithcontinuouslengthoflinewithnojoins.5ftlengthsarejustforrepairs.
However,youcanbuyaftermarket4mmlinesofanylengthandmuchcheaperthanOEMlines.MBalsosellsairlinerepairconnector(junction/fitting)A0003270169
whichcanbeusedtoconnectairline.However,thereisavailablecheapandreliableplastic"pushin"connectorwhichcanbeusedtoeasilyconnectairlineswithoutany
tools.
LeakingFrontStrutAirSpringRepairOptions
CommonIssueLeakingFrontStrutAirSpring
TheFrontSuspensionStrutAirSpringisshowninthenextfigure.ThelowerflaredconicalpartoftheAirSpringprotectiveboot/bellows(n)isthe"AirSpringPlunger".
Theplungermatestothe"SupportBushing/Bearing"whichistheconicalshapedseatontheDamperUnit.
AcommonissuewhenaFrontSuspensionStrutdeflatescompletelyandthecaristhenjackedupsothatthestrutisfullyextendedisthattheAirSpringPlungerseparates
fromtheDamperSupportBearing.
Note:AirsuspensionstrutsonwhichtheAirSpringPlunger(7)isseparatedfromtheSupportBearingcansometimesbefilledwithairagainwithoutproblems.Theydonot
necessarilyneedtobeexchangedforanewsuspensionstrut.Howeverthestrutmustbefilledwhiletheprotectiveboot/bellows(n)isalignedtotheDamperSupport
necessarilyneedtobeexchangedforanewsuspensionstrut.Howeverthestrutmustbefilledwhiletheprotectiveboot/bellows(n)isalignedtotheDamperSupport
Bearing.ThemethodistopressurizethesuspensionstrutusingSTARDiagnosisandatthesametimepresstheAirSpringprotectiveboot/bellowsupwardsasfarasitwill
gotoremoveanycrinkles.Thenpullitsmoothlyandevenlydownwardsandpressontothesupportbearing.Noairmustescapefromtheplungertosupportbearingcontact
surfaceotherwisepressurecannotbebuiltupintheAirSpring.
Repairablefrontstrutdamage(leakingairbetween Picture3:Pulltheairspringplunger(7)
Picture1:Airspringplunger(7)separatedfrom Picture2:Grasptheairspringplunger(7)with
theairspringplunger(7)andthesupportbearing). downwardsbyhandandpressontothesupport
thesupportbearing(conicalshapeatthebottom). thehand.
bearing.
ForanAIRmaticstruttodeflatecompletelytheremaybeacatastrophicfailureofsomeinternalcomponentsuchastheairbag/bladder(h),butitcanalsomeanthatthe
residualpressureholdingvalve(k)isleakingsothatthestrutdeflatesovertime.Thisresidualpressureholdingvalve(k)normallyblocksoffthepressurechamberintheair
springfromthesupplylineandclosesatorbelowaresidualpressureof45bar.Foraleakingresidualpressureholdingvalve(k)tocauseafulldeflation,theairsupplyline
ortherelevantvalveintheLevelControlValveUnit(Y36/6)wouldalsoneedtobeleaking.
AleakingLevelControlValveUnit(Y36/6)onitsownshouldnotcausethestruttodeflatecompletelyastheresidualpressureholdingvalve(k)shouldbefullyclosed
below45bar.
LeakTestLeakingFrontStrut
BeforereplacingasupposedleakyAIRmaticstrut,alwayscarryoutaleaktestontheheadbearingusingsoapywater.Proceedasfollows:
Filltheairspring(usingtheDASorothermeans),andintheprocesspulltheairspringplunger(7)downwardsfirmlybyhandsothattheairdoesnotescapebetween
theairspringplungerandtheDampersupportbearing(picture2and3).
Oncethesuspensionstrutisfilled,carryouttheleaktestontheheadbearingandrepairifnecessary.Arepairkitisavailableforthispurpose.
Afterusingtherepairkitproceedasdescribedabovewhenfillingtheairsuspensionstrut(picture2and3)iepulltheairspringplunger(7)firmlydownwardsbyhand
sothattheairdoesnotescapebetweentheairspringplungerandthesupportbearing.
RepairOptionsLeakingFrontStrut
Iftheheadbearingisnotleakingandtheplungerisfullyseatedonthesupportbearingthentheoptionsareto
ReplacethecompleteAIRmaticstrutwitheither(Note:FortheDIYmethodcontrolclicktoopenanewtabhere[18]
(https://w220.ee/Airmatic#Replacing_Front_Axle_Spring_Strut_.2840.29__AIRmatic).)
AnewOEM(egMBorBilstein)AIRmaticAirSuspensionStrut.(Forpartnumberscontrolclickforanewtabhere[19]
(https://w220.ee/Airmatic#Part_Numbers__AIRmatic_Air_Spring_Struts_.2840.2C_41.29).)
ArefurbishedAIRmaticAirSuspensionStrutsuchasArnotts.(Notelossofdampingoptions.)(Forpartnumberscontrolclickforanewtabhere[20]
(https://w220.ee/Airmatic#Part_Numbers__AIRmatic_Air_Spring_Struts_.2840.2C_41.29).)
AnaftermarketAIRmaticAirSuspensionStrut.
Amechanicalspringversionofthecompletesuspensionstrutwhicheliminatesthepneumaticparts.(Note:Requiresbothsidestobereplacedasaminimum,
andpossiblyallfourwheelsshouldbedonetogether.Thismethodusescleverelectroniccomponentsto'trick'theW220computersintosensingthatan
AIRmaticisactuallyinstalledsothaterrormessagesarenotdisplayed.TheBIGdisadvantageisthelossofairsuspensionridequality,automaticlevellingand
dampingoptions.)
ReplacejusttheAirSpringoftheAIRmaticSuspensionStrut.(Note:ThisisthecheaperoptionbutrequiresdismantlingthefailedSuspensionStrut.Itisagood
optionifthedamperunitisingoodcondition.RefurbishedAirSpringsareavailablefromSuspensionWorkshops.FortheDIYmethodcontrolclicktoopenanewtab
here[21](https://w220.ee/Airmatic#Replacing_the_Air_Spring_in_an_AIRmatic_Strut).)
ReplacingFrontAxleSpringStrut(40)AIRmatic
IfareplacementFrontAxleSpringStrut(40)hasbeenprocureditisquiteaneasytasktoswapthemover.TIPRereadtheTipsSectionbeforestarting,especiallythetip
aboutinstallingthestubscrewsinthedamperunitBBEFOREinstallinginthecar.Controlclickforanewtabhere[22](https://w220.ee/Airmatic#Tips__AIRmatic).
RemovalReplacingFrontAxleAIRmaticSpringStrut(40)
1.Placethefrontwheelsinthestraightaheadposition.
2.Openhood.
3.DepressurisetheAIRmaticsystemusingSTARDAS.(Note:itisnotabsolutelynecessarytodothisstepasitismostlikelythattheAIRmaticstruthaslostits
pressureanyway.JustbecarefulwhenopeningthePressureLinetoreleaseanyresidualairslowly.)
4.Removef32/40A(AIRmaticCompressorfuse)fromtheRelayboxinenginecompartmentright.
5.Removeignitionkey.
6.Jackupthefrontorjustonesideofthecarasrequired.
7.Supportthecaronstands.
8.Removethewheel.
9.UndotheAIRmaticLevelControlSensorrodwhereitattachestothewishbone(10mm).
9.UndotheAIRmaticLevelControlSensorrodwhereitattachestothewishbone(10mm).
10.RemovetheAIRmaticLevelControlSensorfromthecar.(16mmboltwith16mmnutinenginecompartment.)
11.PlaceajackoranadjustablestandunderthelowersuspensiontojustsupporttheweightoftheAIRmaticstrut.(Note:thelowercontrolarmwilldroponcetheAllen
StubScrewsarecompletelyremoved.)
12.SeparatetheAIRmaticFrontStrutfromthelowerballjoint.(Note:TheAIRmaticfrontstrutisattachedtotheballjointofthelowersuspensionarmwithtwostub
screws(5mmhexAllenkeyscrews)onthebottomofthespringstrut.)
13.IfrequiredapplyheattothebottomAllenStubScrews.(Note:Severalpeoplehavereporteddifficultscrewremovalresultinginseveralbrokenhexwrenches,
frustrationorevenstrippedsetscrewsthathadtobedrilledout.Averyeffectivemethodtoremovethescrewsistouseheatfromablowtorch.Amicrotorch
providesanicesmallsharpflamethatiseasilycontrolledastonotcauseanycollateraldamage.)
14.LoosenthetwobottomAllenStubScrews(5mmhexAllenkey).
TIP:Donotfullyremovethestubscrews,justunscrewthemsothataboutfivethreadsareshowing.
Loctitecanbeaddedtotheexposedthreadsbeforeinstallation.(Note:Itisveryeasytostripthethreadwhenstartingthestubscrewsindirtyholesonanold
damperunit.Notcompletelyremovingthestubscrewsduringdisassemblyeliminatesthisproblem.Ifastubscrewmanglesthestartofathread,removetheAir
Struttoaworkbenchandthoroughlycleanthethreadsonbothholes.TheywillbefullofoldLoctitesealer.Thenscrewastubscrewintothe'good'sideand
keepscrewingitallthewaythroughuntilitcomesoutthefarside,andintheprocessreshapingthemangledthread.Dothisacoupleoftimesandthestub
screwshouldthenstartproperly.Itisfareasiertostartthestubscrewsonaworkbenchthanwheninthecar.)
15.RemovetheAIRmaticMultielectricalplugsX62/6orX62/7.(Note:WISsaystopressdownonthespringretainingcliptoreleasetheMultiElectricalConnectors.)
ThenextFigureshowswhattheMultiElectricalConnectorsandtheirSpringRetainingCliplooklike.
16.IfnecessarytheAIRmaticMultielectricalplugsX62/6orX62/7canbereleasedbyprisingtheSpringRetainingClipupwardsasshowninthenextFigure.
17.SeparatetheAIRmaticFrontStrutMultiElectricalConnectorintotwoconnectorsthusreleasingtheAIRmaticFrontStrutsothatitcanberemoved.ThenextFigure
showswhattheMultiElectricalConnectorlookslikebeforeandafterseparating.
18.Undotheuppercontrolarmballjointnut(17mm)untilitreachestheendofitsthreadandleaveinplacetoprotectthethread.
19.Useaballjointseparatortooltoremovetheuppercontrolarmballjoint.
20.Removethepressureairlinefromtheheadofthestrut(10mm).
21.Wraptheexposedairlineconnectorinaplasticbagtoprotecttheendoftheairlinefromcontamination.(Note:observethe'O'ringontheconnector.)
22.Removethethreeuppermountingnuts(13mm)atthestruthead.
23.Removethestrut.Ifyouareluckytheoldstrutwillprettymuchfallout,especiallyifithascollapsed.
InstallationReplacingFrontAxleAIRmaticSpringStrut(40)
TIPRereadtheTipsSectionbeforestarting,especiallythetipaboutinstallingthestubscrewsinthedamperunitBEFOREinstallinginthecar.Controlclickforanewtab
here[23](https://w220.ee/Airmatic#Tips__AIRmatic).
1.Installthenewstrut.Itshouldslipinwithease.
2.Lightlytightenthethreestrutuppermountingnuts.(Note:theywillbetorquedfullyoncethecarisreadytodrive.)
3.Pryuporjackupthelowercontrolarm.
4.Setthebottomofthestrutintoitsballjointsocket.
5.AddsomeLoctiteSealertotheStubScrewthreads.
6.TightenthebottomStubScrews(5mmHexAllenKey).
7.CheckthattheStubScrewsareflushorslightlybelowtheouteredgeofthethreadedhole.
8.Plugintheelectricalconnectionfirmly.
9.Checkthattheelectricalconnectorispluggedincorrectly.(Note:Itcanbedifficulttogetitinstalledcorrectly.)
10.Installtheupperballjoint.
11.Installthelevelcontrolsensorrod.
12.Reinstallthewheel.
13.Installtheairline[5Nm].(Note:checkthe'O'ringandreplaceifnecessary.)
14.Installf32/40A(AIRmaticCompressorfuse)fromtheRelayboxinenginecompartmentright.
15.Jackthecarupslightlyhigher.
16.Removethestand/s.
(Note:Nevercompletelylowerthevehicleiftheairshocksarenotpressurised.)
17.Lowerthejackpartlyuntilthecarisatnormalvehicleheight.(Note:lowervehicleuntildistanceaxlecentretoloweredgeoffenderisabout400mm.)
18.Starttheengineandwaitforatleasttwominutesforeverythingtostabilise.
19.Ifnecessaryalignthebellows.Youmayhavetotakethewheeloffagaintodothisstep.IftheAirSpringbellowsandplungerhaveseparatedfromtheconicalsupport
bearingontheDamperUnittheymustbealignedcorrectly.Thetechniqueisdescribedfullyabove.Insummary,pressthebellowsupwardstowardsthetoptoremove
anycrinkles.Thenpullitfullydownwardsandpressitontotheconicalsupportbearing.
20.FromthecockpitpresstheLevelControlSwitch(N72/1s2)toraisethevehicle.
21.Thecarshouldliftoffthejack.
22.Removethejack.
23.FromthecockpitpresstheLevelControlSwitch(N72/1s2)tolowerthecartothenormalheight.
24.Torquethethreestrutuppermountingnuts[20Nm].
TutorialsReplacingFrontAxleSpringStrut(40)
Excellentreplacementtutorialsforthefrontstrutsareavailablehere:
Mercedes Benz W220 Fro... Mercedes Benz S-Class Fr... Mercedes-Benz S-Class R...
FrontAirSpringReplacement(byDavidProkity). FrontAirShockRemovalandInstallation(byArnott). RearAirShockRemovalandInstallation(byArnott).
http://www.bilsteinus.com/fileadmin/user_upload/user_upload_us/pdfs/E4WM5Y328A00_01.pdf(DE/EN)
http://info.bilsteinus.com/mercedes/(videos)
ReplacingRearAxleSpringStrut(41)AIRmatic
IfareplacementRearAxleSpringStrut(41)hasbeenprocureditisquiteaneasytasktoswapthemover.Ref:WISAR32.25P1016I(MODEL220exceptCODE(487)
ActiveBodyControl(ABC))
PartsDesignationsReplacingRearAxleAIRmaticSpringStrut(41)
RemovalReplacingRearAxleAIRmaticSpringStrut(41)
1.DepressurisetheAIRmaticstrutconcerned(41)usingSTARDAS.(Note:itisnotabsolutelynecessarytodothisstepasitismostlikelythattheAIRmaticstruthas
lostitspressureanyway.JustbecarefulwhenopeningthePressureLinetoreleaseanyresidualairslowly.)
2.Openhood.
3.Removef32/40A(AIRmaticCompressorfuse)fromtheRelayboxinenginecompartmentright.
4.Removeignitionkey.
5.Jackupthefrontorjustonesideofthecarasrequired.
6.Supportthecaronstands.
7.Removethewheel/s.
8.Removecover(arrow)inparcelshelf
9.Unscrewpressurelineconnection(41a).BeWarned:Residualpressureinsuspensionstrutupto3.5barsoifpressurehasnotbeenreleasedatstep1,SLOWLY
unscrewthevalveallowingtheresidualpressuretoescape.TIP:Plugthepressurelineforthedurationoftherepairoperations.[Airsuspensionpressurelinetorear
airspringtorquespec.5Nm]
10.Unscrewnuts(41b).Installation:Fitnuts(41b)thenrefillsuspensionstrutinfullyassembledvehiclebeforetorquingtospecification.TIP:Installation:Tofacilitate
tighteningoperationsandensurethecorrecttorqueonthenuts(41b),itmayproveusefultoremovethetrimfromtheCpillar.[Nut,rearsuspensionstruttobody
torquespec.20Nm]
11.Pulloffgrommetanddisconnectelectricalconnectorofdampingvalveunit(Y53x1/Y54x1)
12.Removebolts(72d)onspringcontrolarmcover(72c).
13.Removeboltedconnection(2)ofsuspensionInstallation:Fitnuts(41b)andtightenstrut(41)onspringcontrolarm(72)afterfillingthesuspensionstrutonavehicle
whichisreadytodrive.[Nut,rearstruttospringcontrolarmtorquespec.110Nm]
14.Removeboltedconnection(2)ofsuspensionInstallation:Fitnuts(41b)andtightenstrut(41)onspringcontrolarm(72)afterfillingthesuspensionstrutonavehicle
whichisreadytodrive.[Nut,rearstruttospringcontrolarmtorquespec.110Nm]
15.Removeboltedconnection(1)ofspringcontrolarm(72)onrearaxlecarrier
16.Removeboltedconnection(3)ofthrustarm(4)onrearaxlecarrier
17.Pulldowntrackcontrolarm(72)andremovestrutassembly(41)byloweringitandpullingitouttotheside.
InstallationReplacingRearAxleAIRmaticSpringStrut(41)
1.Installinthereverseordertoremoval.
2.FillsuspensionstrutsaffectedusingSTARDIAGNOSIS.[Pressurizeto5bar.]TIP:Duringrechargingthewheelsshouldneverbeincontactwiththefloorrefilling
withthesuspensioncompressedleadstodestructionoftheairsuspensionbellowsinthestrut(41).
3.CheckAIRmaticforleaks.
ReplacingtheAirSpringinanAIRmaticStrut
AsdescribedaboveintheIssuesandTroubleShootingSectionaverycommonreasonforaleakingstrutisdamageinthestrut'srubberairbag/bladder(h).
ItispossibletopurchaseoneBayarefurbishedFrontAirSpringwhichisthetoppartofanairsuspensionstrutforaroundEUR120andmountittotheoriginaldamperunit
(thelowerpartofanairsuspensionstrut).
ThisrequirestheStruttoberemovedfromthecarandtheAirSpringtobeseparatedfromtheDamperunitbypartlydismantlingtheAirSpring.
ItappearsthatjustreplacingtheRearAirSpringinarearairsuspensionstrutisnotsuitableforaDIYproject.(Tobeconfirmed.)
DismantlingFrontAirSpring
IdentificationofPartsControlclicktoopenanewtabhere[24](https://w220.ee/Airmatic#Components__AIRmatic)toidentifythepartnamesfortheFrontAxle
AIRmaticAirSuspensionStrut(40).
RemovalControlclicktoopenanewtabhere[25](https://w220.ee/Airmatic#Removal__Replacing_Front_Axle_AIRmatic_Spring_Strut_.2840.29)toseethemethodfor
removingthecompleteFrontAxleAIRmaticSpringStrut(40).TIPRereadtheTipsSectionbeforestarting.Controlclickforanewtabhere[26]
(https://w220.ee/Airmatic#Tips__AIRmatic).
SeparatingAirSpringfromtheDamperUnitFrontAxleAIRmaticAirSuspensionStrut
1.Removetheepoxy/masticusingahammerandascrewdriver.(TIP:Ifyouaredoingthiswiththestrutstillinthecar,avoidgettingpiecesofepoxy/masticinthe
engine.)
2.Usingaspecialtool(controlclicktoopenanewtabhere[27](https://w220.ee/Airmatic#Tools_Required_
_Replacing_Air_Spring_in_Front_Air_Suspension_Strut_.2840.29))unscrewtheresidualpressureholdingvalve(k).
3.Ifrequiredclosetheopeningoftheresidualpressureholdingvalve(k)withashortboltM8,sothatnodirtcanpenetrateintotheairsuspensionstrut.
4.Usingaspecialtool(controlclicktoopenanewtabhere[28](https://w220.ee/Airmatic#Tools_Required_
_Replacing_Air_Spring_in_Front_Air_Suspension_Strut_.2840.29))fitthetooltotheStrut.
5.TightenthecentralnuttotheplatefromtheinsideandthiswillwinddowntheboltpushingtheAirSpringtopmetaldiscinwardsslightlyreleasingthesnapring.
6.Removethesnapring.(TIP:Useasmallscrewdrivertohelpremovethecircliplocksnapringbutmakesureitdoesnotcauseanyscratchesandburrs,otherwisethe
sealingofthenewlockringmaybecompromised.Removeanysharpedgesorburrsifrequired.)(Note:anewcircliplocksnapringisprovidedinthetopsealkit,see
below.)
7.Removethetool.
8.Removethetopsealmetaldisccoverwithits'O'ring.(Note:Runasmallscrewdriveraroundtheedgeofthediscandthenkeepmanipulatingthediscuntilitstartsto
comefree.Useasmallscrewdrivertoleverthediscout.Averystrongmagnetcanhelp.)
ThenexttwofiguresshowtheinsideviewoftheTopSealMetalDiscCoverwith'O'ring(withpartnumber2203280621or2203280621justvisibleinthe
secondfigure).(Note:anewTopSealMetalDiscCoverandanew'O'ringareprovidedinthetopsealkit,seebelow.AnewTopSealMetalDiscCoveranda
new'O'ringareoftenprovidedwithanew/refurbishedAirSpring.)
9.InspecttheinsideofthetopoftheFrontStrutforanysharpedgesorburrsandremoveifrequired.
10.Drilla4mmholeandifnecessaryinsertascreworsimilardevicepartwayintothenylonplugwhichcanthenbepulledout.(Note:anewnylonplugisavailablewith
partnumberTBD.)
ThisiswhattheinsideoftheTopoftheFrontStrutlookslikeafterremovingthenylonplug.
11.Useanairimpactdrivertoundothelocknutonthetopofthedamperpistonrod(e).(Note:unfortunatelyitisessentialtouseanimpactwrenchasthepistonrodin
thedamperunitcannotberestrainedfromturning.Theimpactwrenchshocksthenutundone.)
12.Removethecompleteairspringfromthedamperunit.
13.FromtheinsideoftheAirSpringusealongpieceofrodortubingtopressouttheuppermountrubberbush.
Thenextfiguresshowwhattheuppermountrubberbushlookslikefromseveralviews.Thispartcamefroma2003updatemodelW220S500L.
OutsideviewofthetopofaFrontAirSpringwiththeuppermountrubberbushremoved.Thispartcamefroma2003updatemodelW220S500L.
OutsideviewofthetopofaFrontAirSpringwiththeuppermountrubberbushremoved.Thispartcamefroma2003updatemodelW220S500L.
InsideofthetopofaFrontAirSpringwiththeuppermountrubberbushremoved.
Theyellowarrowpointstotheholegoingthroughtheuppermountrubberbushforthedamperpistonrod(e).
ThebluearrowpointstotheinsideoftheAirSpringfortherubberairbellows(h).
TheredcircleshowsthethreadedbrassairinlettotheAirSpring.
ReassemblyFrontAirSuspensionStrut(40)
1.Fastentheairbag/bladder(h)tothestruttopusingthe1stcrimpring.
ThenextFiguresshowthesteelsupportringforthelowerstruttube(a),whichprovidessupportforthe2ndorlowercrimpring.
2.Installthestruttube(a)intotheairbag/bladderandsecurewiththe2ndcrimpring.
ThenextFigureshowstherubberairbag/bladderwhichismountedontheoutsideofthestruttube(a)andisheldinplacebymetalcrimprings.
Notes:
Thebottomendorplungerofthelowerstruttube(a)istaperedwhichisforsealingtothesupportbearingonthedamperunit.
Note:theAirmaticstrutcanleakairfromthebottomofthelowersectionifnotseatedagainsttherubberofthedamperunitcorrectly.
3.ChecktheSealbetweenthedamperandtheairspring.
ThenextFigureshowsthebottomairspringtodampersealopenandfullyseated.
4.Installtopalloydustcover.
ThenextFigureshowsthetopdustsealalloycoverwhichiscrimpedtothestruttop.
5.Installtheprotectiveboot/bellowstothetopdustsealalloycover.
6.Thoroughlycleanthedamperunitbeforeitisfittedintotheairspring.
ThenextFigureshowsacloseupofthestrutdamperwiththebumpstopbuffer(i)andbumpstopcover.Thedamperisfittedaftertheairspringhasbeen
assembled.Itslidesthroughthestruttopandthenhastheuppermountrubberbushandnutfittedfollowedbythenyloncoverandthenthetopmetaldisccover
andlockring.Notethelargeconicalrubbersupportbearingwhichprovidestheairspringtodamperseal.
7.PreparethestruttopplatetotaketheDamperUnit.
Thenextthreefiguresshow
(leftimage)thestruttopplatewiththeholeforthedamper,
(centerimage)thestruttopplatewiththeuppermountrubberbushinplacewaitingforthenylocnut,(Note:animpactwrenchisusedtotightenthenut
(withLoctiteapplied)tothedamperpistonrod.)
(rightimage)thestruttopwiththenyloncoverplacedoverthenut.
8.Thenexttwofiguresshowthemetaldisccoverwiththe'O'ringinstalled(TIP:usesilicongreasetoensureitisleakfree)andthelockringreadytobefittedusingthe
struttopsealtool.
9.Installtheresidualpressureholdingvalve(k)usingthecommercialtoolorDIYmodifiedspanner.
10.Supportthestrutverticallyandfillthetopofthestrutwithablackbutylmastictoreducevibrationdamagetotheairinletvalve.
TIP:Ifapourablebutylmasticcannotbesourced,Sikamanufacturearangeofbutylmasticsealerswhichcanbeextrudedinthinlayers(5mmthick).Usea
TIP:Ifapourablebutylmasticcannotbesourced,Sikamanufacturearangeofbutylmasticsealerswhichcanbeextrudedinthinlayers(5mmthick).Usea
spatulatosmooththelayerevenlyandthenleaveittoset.Repeatthelayeringprocessuntilthecavityisfilled.TheresultisnotasneatastheOEMbutitdoes
thejob.IfrequiredtheextrudedlayerstechniquecanbedonewiththeAirStrutinstalledinthecarasthecompoundisquiteviscousandwillnotrun.
ATopSealRepairKit(Includes:SteelCap,BrassValve,andSpringClip)isavailablewithpartnumberA2203202538orA2203202538.
ToolsRequiredReplacingAirSpringinFrontAirSuspensionStrut(40)
Commercial1/4"driveAIRmaticResidualPressureHoldingValveTool.(ItisusedtoremoveandinstallthebrassResidualPressureHoldingValvesateachoftheair
inletstotheFrontAirSuspensionStruts.)
AlternativeDIYAIRmaticResidualPressureHoldingValveTool.Modifyeitheraor3/8"spannerbygrindingitdowntofittheResidualPressureHoldingValve.
ThecriticaldimensionsoftheResidualPressureHoldingValveareshowninthenextfigure.
Commercialstruttopsealtool.Foranexamplesee[29](http://w220.ee/Special_Tools#Airmatic_Strut_Seal_Remover_Tool)
AlternativeDIYhomemadestruttopsealtool.Hereishowtomakeonefroma150mmx150mmpieceof6mm(1/4")steelplate.
1.AccuratelymarkupthesteelplateasperthenextFigurewhichshowsthemarkupdimensionsfortheDIYAIRmaticFrontStrutTopSealRemoverTool.
1.Drawthetwodiagonalstoestablishthecentreoftheplate.
2.Markwithacentrepop.
3.Setadividerto61.5mmradius.
4.Drawacirclewiththedivideraroundthecentrepopproducingthepitchcirclediameterof123mm.
5.Centrepopthefirstholeononeofthediagonals.
6.Usethedividerstillsettoaradiusof61.5mmandmarksixarcsaroundthecircumferenceofthePCD.ThisdividesthePCDintosixequalchords.
(Alternativelysetthedividerto106.5mmandscribeacrossthePCDintwoplaces.)
7.Centrepoptherequiredintersectionsfortheothertwo8mmholes.
8.Visuallycheckthatthecentrepopmarksmatchthepitchcirclediameter(pcd)ofthestruttopplatemountingbolts.
9.Drillthethreeoff8mmholes.
10.Drillone10mmholeinthecenter.
11.Obtainthreeoff120mmlong8mmboltsforthethree8mmholes.
12.Usethree8mmjoinernutstoattachthe8mmboltstothestruttop.(Alternativelyfouroff8mmnutscanbeweldedtogethertomakeoneoff'long'nut.)
13.Obtainoneoff150mmlong10mmboltforthecenter10mmhole.
14.Threadanutrighttothetopofthe10mmboltandaddaflatwasherwithalittlebitofgrease.
Impactdriver(Note:isabsolutelyessentialforremovingthenutatthetopofthedamperunit.)
Retrievedfrom"https://w220.ee/index.php?title=Airmatic&oldid=4763"
Thispagewaslastmodifiedon16December2016,at08:51.

1994 S320 S420 S500 Owner's Manual

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12/18/2016 AirmaticW220Encyclopedia

Dampingswitch(facelift). Dampingswitch(prefacelift). Levelanddampingswitch(producedupto08/99).

Repairsectionofairline(A2203271045).Price Airlinerepairconnector(A0003270169).Price 4mm"pushin"pneumaticfitting.Alternativeto

FrontAirSpringReplacement(byDavidProkity). FrontAirShockRemovalandInstallation(byArnott). RearAirShockRemovalandInstallation(byArnott).

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1994 S320 S420 S500 Owner&#39;s Manual

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1994 S320 S420 S500 Owner&#39;s Manual

Încărcat de

Drepturi de autor:

Formate disponibile

12/18/2016 AirmaticW220Encyclopedia

Dampingswitch(facelift). Dampingswitch(prefacelift). Levelanddampingswitch(producedupto08/99).

Repairsectionofairline(A2203271045).Price Airlinerepairconnector(A0003270169).Price 4mm"pushin"pneumaticfitting.Alternativeto

FrontAirSpringReplacement(byDavidProkity). FrontAirShockRemovalandInstallation(byArnott). RearAirShockRemovalandInstallation(byArnott).

S-ar putea să vă placă și

1994 S320 S420 S500 Owner's Manual

1994 S320 S420 S500 Owner's Manual