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

MODEL 220 except CODE (487) Active Body Control (ABC) 

Shown on right air suspension strut 

Fig 1: Identifying Pressure Line Connection, Residual Pressure Retaining Valve And Circlip

Fig 2: Sealing Top Air Suspension Strut (1 Of 2)

Fig 3: Sealing Top Air Suspension Strut (2 Of 2)

Fig 4: Identifying Air Spring Plunger And Support Bushing

	Removing
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	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	Raise vehicle to the extent that work can still be carried out in the engine compartment.
3	Discharge air suspension struts using STAR DIAGNOSIS	STAR DIAGNOSIS diagnosis system
	Notes on AIRmatic		AH32.22-P-1000-02I
4	Unscrew pressure line connection (1) and place pressure line to the side
5	Cover engine compartment	When dissolving the casting compound, flying around parts can enter into the openings of the engine.
	Risk of injury  to skin and eyes caused by handling hot or glowing objects.	Wear safety gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
6	Warm up casting compound with hot air blower	Heat adhesive until it softens. At the same time check the hardness with a screwdriver. Hot air blower
7	Separate casting compound with screwdriver	Always remove separated parts of the casting compound with vacuum cleaner.
8	Unscrew residual pressure retaining valve (2) with adapter	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.
		Adapter	Fig 6
9	Always remove remaining casting compound with screwdriver	There must be no burrs and dirt particles.
10	Screw in the bolts (010a) of the removal and extraction tool (010) in stages corresponding to the sequence of pictures and secure with cotter pins	Only one nut (5) must always be undone and replaced by a bolt (010a) of the removal and installation tool (010). When releasing several nuts (5), the air suspension strut can slip out toward bottom and can be damaged. Installation:  Install new nuts. (5).
		Removal/installation tool	Fig 5
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)	Make sure it does not cause any scratches and burrs, otherwise the sealing ring of the new cover (4) is damaged when installing.
13	Release removal and installation tool (010) and remove cover (4) with bar magnet	Check surfaces at air suspension strut and the groove of the circlip (3) for sharp edges. Remove sharp edges if required.
	Install
14	Insert new cover (4)	Apply grease paste onto the sealing ring of the new cover (4) Do not use any oils and grease (mineral oil products), these can damage the sealing ring and lead to leakage of the air suspension strut.
15	Press in cover (4) with removal and installation tool (010)	When pressing in, ensure that the new cover (4) is pressed in evenly and is not tilted. Otherwise the sealing ring of the cover (4) is damaged and this leads to the leakage of the air suspension strut.
16	Fit circlip (3)	Install new circlip (3).
17	Unscrew cotter pins of the bolts (010a) of the removal and installation tool (010) and remove bolt (010a) in the reverse installation sequence	Fit on nuts (5) by hand and after filling the air suspension strut tighten in curb condition. Only one bolt (010a) of the removal and installation tool (010) must be undone and replaced by a nut (5). When several bolts (010a) are undone the air suspension strut can slip downwards and be damaged.
		Model 220 except 220.875	*BA32.25-P-1001-04B
		Model 220.875	*BA32.25-P-1001-04C
18	Glue upper center console of air suspension strut in the engine compartment	The surfaces must be free of grease before painting.
	Risk of explosion  caused by paint vapors igniting. Risk of poisoning  caused by inhaling paint vapors.	No smoking! No open flames! Use respiratory protection, protective clothing, gloves, safety goggles and skin cream. Ensure that the area is well ventilated.	AS98.00-Z-0002-01A
19	Coat damaged surfaces at air suspension top section with primer filler and paint with black acrylic paint	Let painted surfaces dry.
	Notes on paintwork repairs		AH98.00-P-9408-02A
20	Unscrew bolt M8 (6) from the opening of the residual pressure retaining valve (2) and screw in new residual pressure retaining valve (2) with adapter	Attach residual pressure retaining valve (2) by hand and tighten with adapter .
		Adapter	Fig 6
		Model 220 except 220.875	*BA32.25-P-1013-04B
		Model 220.875	*BA32.25-P-1007-04C
21	Screw on pressure line connection (1)	Check O-ring of pressure line for damage and replace if required.
		Model 220 except 220.875	*BA32.25-P-1003-04B
		Model 220.875	*BA32.25-P-1002-04C
22	Lift vehicle further	Raise the vehicle until there is good access to the bellows (7) of the air suspension strut.
23	Align bellows (7), for this step press the bellows (7) toward top and pull in released position toward bottom.	When working on the air suspension strut, unintended wrinkle formations at the bellows (7) can occur. The wrinkle formations must be eliminated, otherwise this can lead later to a failure of the air suspension.
24	Pressurize air suspension strut using STAR DIAGNOSIS	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. When filling the air spring plunger (8) must be pulled downwards and pressed onto the support bearing (9). No air must escape at the contact surface (arrow) otherwise no pressure can be built up in the air suspension strut. STAR DIAGNOSIS diagnosis system
25	Check top air suspension strut for leaks	Spray repaired point with soap water. Pay attention to bubble formation during the rocking at front end.	AR32.22-P-8100I

STRUTS

STRUTS

Fig 5: Identifying Removal, Installation (220 589 00 61 00)

Fig 6: Identifying Adapter (220 589 00 09 00)