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2002-2009 MERECEDES BENZ E-CLASS
(W211 CHASSIS) A-2536 / A-2559
REAR AIR SPRING REPLACEMENT
Congratulations on your selection to purchase an Arnott Air Suspension System. We at
Arnott Air Suspension Systems are proud to offer a high quality product at the industry’s
most competitive pricing. Thank you for your confidence in us and our product.
Proper installation is essential to experience and appreciate the benefits of this system.
Please take a moment to review these installation instructions before you begin to install
this system on your vehicle.
It is equally important to be aware of all necessary safety measures while installing your
new Air Ride System. This includes proper lifting and immobilizing of the vehicle and
isolation of any stored energy to prevent personal injury or property damage.
“Engineered to Ride, Built to last”
VERY IMPORTANT!!
THESE AIR SPRINGS CONTAIN A SOLENOID VALVE. ONCE
INFLATED; ONLY THE “MERCEDES DAS STAR” DIAGNOSTIC
COMPUTER CAN DEFLATE THE AIR SPRINGS.
FIGURE 10-0
The Arnott Inc. (A-2536/A-2559) Air Spring re places the OEM Air Spring;
eliminating the need
for an air reservoir. (FIGURE 10-0)
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2002-2009 MERECEDES BENZ E-CLASS
(W211 CHASSIS) A-2536 / A-2559
REAR AIR SPRING REPLACEMENT
WARNING: The air suspension system is under pressure (up to 10 bar, or
150 lbf/in ) verify pressure has been relieved and disconnect power to the air ride
system prior to dis-assembly. Do not allow dirt or grease to enter the system.
Always wear standard protective hand, ear, and eye protection when servicing the
air suspension system.
Kit contains:
PARTS LIST
P/N QTY DESCRIPTION
A-2536/A-2559 2 REAR AIR SPRING
General information:
* Not to be stored below 5 0F (-15 0C) and above 122 0F (50 0C).
*Avoid damage to air lines and cables.
*Removal and installation is only to be performed by full qualified personnel.
*Use car manufacturer’s diagnostic software.*CAUTION: Damage to the vehicle
and shock assembly can be incurred if work is carried out in a manner other than
specified in the instructions or in a different sequence.
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2002-2009 MERECEDES BENZ E-CLASS
(W211 CHASSIS) A-2536 / A-2559
REAR AIR SPRING REPLACEMENT
REAR SHOCK REMOVAL:
NOTE: REAR AIR SPRING REMOVAL/INSTALLATION IS FOR BOTH THE
REAR RIGHT AND LEFT AIR SPRING.
The ignition must remain switched off during the shock removal and
replacement.
1.1 SET STEERING TO STRAIGHT AHEAD.
1.2 REMOVE POSITIVE BATTERY TERMINAL BEFORE STARTING WORK
Use lifting platform (hoist) that is capable of raising the body separately
from the wheels, lift body at the lifting points prescribed by the vehicle
manufacturer.
Vehicle slippage can cause danger to life and limb.
3.0 RAISE VEHICLE.
4.0 REMOVE REAR TIRE(S). (FIGURE 10-1)
FIGURE 10-1
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(W211 CHASSIS) A-2536 / A-2559
REAR AIR SPRING REPLACEMENT
NOTE: Air pressure! Release slowly and allow pressure to escape
5.0 DISCONNECT THE AIRLINE AND THE MOUNTING NUTS FROM THE AIR
BLOCK, AND MARK AIR LINES. (Figure 10-2).
FIGURE 10-2
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REAR AIR SPRING REPLACEMENT
6.0 AFTER AIR LINES ARE REMOVED, UNPLUG AIR SPRING V A LVE WIRING.
(FIGURE 10-3)
FIGURE 10-3
7.0 REMOVE BOLTS FROM FENDER WELL. (FIGURE 10-4)
FIGURE 10-4
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(W211 CHASSIS) A-2536 / A-2559
REAR AIR SPRING REPLACEMENT
8.0 REMOVE PUSH PINS FROM FENDER WELL, EXPOSING SENSOR
JUNCTION BLOCK. (FIGURE 10-5)
FIGURE 10-5
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(W211 CHASSIS) A-2536 / A-2559
REAR AIR SPRING REPLACEMENT
9.0 MARK CONNETIONS TO ENSURE PROPER PLACEMENT ON REASSEMBLY,
REMOVE RETAINING CLIP A ND UNPLUG SENSOR LINES.
(FIGURE 10-6)
FIGURE 10-6
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(W211 CHASSIS) A-2536 / A-2559
REAR AIR SPRING REPLACEMENT
10.0 REMOVE SENSOR LINES FROM BRACKETS. (FIGURE 10-7)
FIGURE 10-7
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(W211 CHASSIS) A-2536 / A-2559
REAR AIR SPRING REPLACEMENT
11.0 REMOVE AIR SPRING BOLTS FROM THE LOWER CONTROL ARM.
(FIGURE 10-8)
FIGURE 10-8
12.0 REMOVE THE LOWER SHOCK BOLTS. (FIGURE 10-9)
FIGURE 10-9
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REAR AIR SPRING REPLACEMENT
13.0 SUPPORT EXHAUST, AND LOOSEN AND REMOVE EXHAUST FLANGE
BOLTS. (FIGURE 10 -10)
FIGURE 10-10
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REAR AIR SPRING REPLACEMENT
14.0 SUPPORT EXHAUST WHILE REMOVING RUBBER HANGERS, AND
REMOVE EXHAUST. (FIGURE 10-11)
FIGURE 10-11
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REAR AIR SPRING REPLACEMENT
15.0 EXHAUST REMOVED. (FIGURE 10-12)
FIGURE 10-12
16.0 REMOVE DRIVESHAFT SAFETY BAR. (FIGURE 10-13)
FIGURE 10-13
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REAR AIR SPRING REPLACEMENT
17.0 REMOVE TWO BOLTS HOLDING DRIVESHAFT BLOCK, AND REMOVE
PILLOW BLOCK. (FIGURE 10-14)
FIGURE 10-14
18.0 REMOVE REAR DRIVESHAFT BOLTS. (FIGURE 10-15)
FIGURE 10-15
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REAR AIR SPRING REPLACEMENT
19.0 SLIDE DRIVESHAFT TOWARD FRONT OF VEHICLE AND REMOVE.
(FIGURE 10-16)
FIGURE 10-16
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20.0 LOOSEN BOLTS AND REMOVE HEAT SHIELD. (FIGURE 10-17)
FIGURE 10-17
21.0 REMOVE BOLTS FROM ROCK GUARD. (FIGURE 10-18)
FIGURE 10-18
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REAR AIR SPRING REPLACEMENT
22.0 REMOVE ROCK GUARD. (FIGURE 10-19)
FIGURE 10-19
23.0 REMOVE CALIPER CLIP, AND REMOVE BOLT FROM BRAKE SENSOR.
(FIGURE 10-20)
FIGURE 10-20
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REAR AIR SPRING REPLACEMENT
24.0 UNPLUG BRAKE SENSOR CABLE. (FIGURE 10-21)
FIGURE 10-21
25.0 REMOVE CAP FROM CALIPER MOUNTING BOLT, LOOSEN BOLT.
(FIGURE 10-22)
FIGURE 10-22
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REAR AIR SPRING REPLACEMENT
26.0 REMOVE CALIPER, AND SUSPEND WITH ZIP TIES. (FIGURE 10-23)
FIGURE 10-23
CAUTION! DRAIN FILLER HOSE OF GASOLINE!
27.0 LOOSEN FILLER NECK CLAMP, AND REMOVE FILLER HOSE.
(FIGURE 10-24)
FIGURE 10-24
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REAR AIR SPRING REPLACEMENT
28.0 THE REAR CROSSMEMBER BOLT POINTS. (FIGURE 10-25)
FIGURE 10-25
FIGURE 10-25
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REAR AIR SPRING REPLACEMENT
29.0 REMOVE THE (FOUR) REAR CROSSMEMBER MOUNTING BOLTS.
(FIGURE 10-26
FIGURE 10-26
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REAR AIR SPRING REPLACEMENT
30.0 WITH VEHICLE ON LIFT, SUPPORT CROSSMEMBER ASSEMBL Y ON
STANDS, AND RAISE VEHICLE TO ACCESS SPRINGS. (FIGURE 10-27)
FIGURE 10-27
Use lifting platform (hoist) that is capable of raising the
body separately from the wheels, lift body at the lifting
points prescribed by the vehicle manufacturer.
Vehicle slippage can cause danger to life and limb.
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REAR AIR SPRING REPLACEMENT
31.0 LOCATE, LOOSEN, AND REMOVE SWAYBAR BOLTs. (FIGURE 10-28)
FIGURE 10-28
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REAR AIR SPRING REPLACEMENT
32.0 RAISE SWAYBAR TOWARDS REAR OF VEHICLE. (FIGURE 10-29)
FIGURE 10-29
33.0 LOOSEN, AND REMOVE BOLTS FROM AIR RESEVOIR. (FIGURE 10-30)
FIGURE 10-30
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34.0 REMOVE OLD AIR SPRING AND RESIVIOR. (FIGURE 10-31)
FIGURE 10-31
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REAR AIR SPRING REPLACEMENT
35.0 REPLACE RETENTION CLIP WITH NEW CLIP PROVIDED ON THE UPPER
MOUNT. (FIGURE 10-32)
FIGURE 10-32
36.0 WITH THE AIR SPRI NG REMOVED FROM THE VEHICLE, REMOVE THE AIR
LINE FROM AIR SPRING. (FIGURE 10-33)
FIGURE 10-33
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2002-2009 MERECEDES BENZ E-CLASS
(W211 CHASSIS) A-2536 / A-2559
REAR AIR SPRING REPLACEMENT
REAR SPRING INSTALLATION:
Torque nuts and bolts to the manufactures specification.
1.0 LOWER SW AY BAR INTO POSITION > TIGHTEN BOLTS
2.0 LOWER CAR ONTO CROSSMEMBER ASSEMLBY > TIGHTEN MOUNTING BOLTS
X4
3.0 PLUG IN SAS AIR RIDE ELECTRICAL PLUG
4.0 ATTACH FUEL TANK FILLER HOSE > TIGHTEN CLAMP
5.0 INSTALL ROCK GUARD
6.0 RE-INSTALL THE REAR BRAKE CALIPER.
6.1 INSTALL CALIPER, TIGHTEN THE BOLT ON THE BACKSIDE OF THE
CALIPER
6.2 RE-CONNECT THE SENSOR CONNECTOR > RE-INSTALL THE
SENSOR BRACKET BOLT
6.3 INSTALL RETAINING CLIP
7.0 INSTALL HEAT SHIELD
8.0 INSTALL DRIVESHAFT
9.0 INSTALL DRIVESHAFT BLOCK
10.0 INSTALL DRIVESHAFT SAFETY BAR
11.0 INSTALL EXHAUST
12.0 INSTALL SENSOR LINES I N BRACKETS
13.0 PLUG IN SENSOR CONNETORS
14.0 INSTALL PUSH PINS AND BOLTS IN FENDER
15.0 PLUG IN AIR RIDE WIRING
16.0 INSTALL AIR LINES TO METER BLOCK
17.0 INSTALL METER BLOCK
18.0 ALIGN LOGO AND AIR FITTING OUTBOARD, TO WARDS WHEEL (FIGURE 10-34)
FIGURE 10-34
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19.0 COMPRESS AIR SPRING TO INSTALL. (FIGURE 10-35)
FIGURE 10-35
20.0 LINE UP MOUNT TO LOWER CONTROL ARM. ( FIGURE 10-36)
FIGURE 10-36
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21.0 INSTALL, AND TIGHTEN MOUNTING BOLT. (FIGURE 10-37)
FIGURE 10-37
22.0 ENGAGE TOP CLIP, AND INSTALL AIR LINE. (FIGURE 10-38)
FIGURE 10-38
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23.0 CONNECT AIR SPRING VALVE WIRING. (FIGURE 10-39)
FIGURE 10-39
24.0 INSTALL REAR TIRE; TIGHTEN LUG NUTS TO MANUFACTURERS’
SPECIFICATION.
25.0 REMOVE JACK STANDS > LOWER VEHICLE TO STANDA RD VEHICLE
FROM THE LIFTING PLATFORM.
25.0 LOWER VEHICLE TO STA NDARD VEHICLE HEIGHT FROM THE LIFTING
PLATFORM.
27.0 RE-CONNECT BATTERY TERMINAL.
Never under any circumstances allow the vehicle to be fully lowered from the lifting
platform (hoist) with the air suspension depressurized.
28.0 START ENGINE, WAIT 2 M INUTES, OPERATE THE RAISING FUNCTION OF THE
CARS ELECTRONICS.
29.0 INITIALLY LOWER LIFTING PLATFORM SLOWLY AND ONLY COMPLETELY WHEN
THE VEHICLE RISES OF ITS OWN ACCORD.
30.0 CHECK SHOCK FOR LEAKS.
31.0 INSTALLATION COMPLETE.
VERY IMPORTANT!!
THESE AIR SPRINGS CONTAINS A SOLENOID VALVE. ONCE
INFLATED; ONLY THE “MERCEDES DAS STAR” DIAGNOSTIC
COMPUTER CAN DEFLATE THE AIR SPRINGS.
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