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CAR
LEVEL CONTROL, SERVICE INSTALL
Rear
springs for trailer operation are to be replaced by standard ones.
All
except Models 35, 36, 38, 45, 46 and 48
Unbolt
one shock absorber in luggage compartment and remove damping parts.
Turn
back luggage compartment floor covering.
Raise
vehicle.
Support
rear axle arm using hydraulic jack and unbolt shock absorber.
Remove
shock absorber. Lever out using mounting iron if required.
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Insert
shock absorber for car level control in bracket on rear axle.
Position
vertically - pressure line connection must face rear of vehicle - and tighten
fastening bolt to 70 Nm/51.6 lbf. ft.
Gently
tap in fastening bolt until it rests against rear axle arm using a plastic
mallet, if required.
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Lower
vehicle not quite fully - wheels should cushion slightly.
Place
washer and rubber buffer on shock absorber.
Insert
shock absorber into shock absorber dome.
Place
rubber buffer and washer on shock absorber.
Screw
on hex nut - maintain adjustment dimension A = 6 mm/0.24 in.
Install
protective cap.
Remove
protective cap and shock absorber mounting on other side of vehicle.
Raise
vehicle.
Unbolt
and remove shock absorber from rear axle arm.
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Mount
shock absorber for car level control on rear axle arm, incline slightly to
rear and tighten to 70 Nm/51.6 lbf. ft.
The
pressure line connection faces the rear.
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On
Vehicles up to Model Year '86:
Drill
Æ 8 mm/0.32 in. hole for filler valve with screw cap
from underneath in rear right vehicle underbody according to dimensions
alongside.
On
Vehicles as of Model Year '86:
Drill
Æ 12 mm/0.47 in. hole for filler valve with plug-in
cap from underneath in rear right vehicle underbody according to dimensions
on right.
Deburr
drilled hole and cover with paint.
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Insert
cable clamps in rear end panel.
Mount
2 retaining clips on left wheel housing.
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Mount
3 retaining clips on right wheel housing as shown in illustration.
Cut
pressure lines to length, ensuring clean cuts.
Right
pressure line approx. 150 cm/5 ft.
Left
pressure line approx. 350 cm/11.5 ft.
Note:
If
pressure lines are already cut to length, use the correct line from shock
absorber to filler valve (different lengths for right and left).
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Push
connecting parts on to pressure lines.
Illustration
shows connections already pushed on, up to Model Year '86.
1 Rubber seal
2 Metal sleeve
3 Pressure line
4 Union nut
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Insert
pressure line with connecting parts into corresponding shock absorber and
tighten union nuts to 3 Nm/2.2 lbf. ft.
On
Vehicles as of Model Year '86:
Place
pressure line onto shock absorber.
Insert
left hand pressure line into the two retaining clips on wheel housing and
into cable clamps on rear end panel.
Insert
right hand pressure line into retaining clips and lead to filler valve.
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Cut
pressure line to required length for filler valve to be installed - ensure
clean cuts at ends.
Note:
If
pressure lines are already cut to length, use correct line from shock
absorber to filler valve (different lengths for right and left).
Insert
pressure line with connecting parts in filler valve, tighten union nuts to 3
Nm/2.2 ft.lbf.
On
Vehicles as of Model Year '86:
Place
pressure line onto filler valve.
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Check
system for leaks.
Inflate
system to max. 800 kPa (8 bar)/116 psi and check all connections for leaks.
Reduce
pressure in shock absorber to 80 kPa (0.8 bar)/11.6 psi.
Insert
filler valve with washer and rubber seal in vehicle underbody from
underneath.
On
Vehicles as of Model Year '86:
Insert
filler valve into vehicle underbody until it catches.
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Lower
vehicle.
Fasten
filler valve in luggage compartment with washer and hex nut.
On
Vehicles as of Model Year '86:
Push
expanding ring onto filler valve, so that valve remains fixed.
Note:
On
vehicles with no trailer towing facility or with luggage compartment cover,
make hole of approx. 10 mm/0.4 in. Æ for filler valve
passage using hollow punch.
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Fasten
sticker with air pressure details to tail gate as shown in illustration.
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Instructions
for Filling the System
(See
also information in Owner's Manual)
Prior
to loading, the unladen vehicle should be on a level surface and the empty
system should be filled to 80 kPa (0.8 bar)/11.6 psi.
Measure
the height of the rear bumper above the ground.
Deduct
5 cm/1.97 in. from this figure and note the new figure in the Owner's Manual.
If
this figure is not achieved when the vehicle is laden, increase pressure
until it is - do not exceed 500 kPa (5 bar)/72.5 psi.
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Models
35, 36, 45 and 46
Turn
back rear right load floor covering inwards.
Drill
Æ 8 mm/0.32 in. for filler valve with screw cap or Æ 12 mm/0.48 in. hole for filler valve with snap-on cap in rear right
load compartment according to dimensions alongside.
Deburr
drilled hole and cover with paint.
On
vehicles with load compartment cover:
Make
Æ 10 mm/0.4 in. for filler valve passage in load
compartment cover using hollow punch.
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Raise
vehicle.
Raise
rear axle arm using hydraulic jack.
Unbolt
shock absorber from rear axle arm and vehicle underbody.
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Bolt
new shock absorber onto vehicle underbody - the pressure line connection
faces outwards on the right hand shock absorber and inwards on the left hand
one.
Place
washer and rubber buffer on shock absorber.
Insert
shock absorber in bracket on rear axle arm and mount rubber buffer with
washer.
Tighten
hex nut to 10 Nm/7.4 lbf. ft.
Tighten
shock absorber fastening bolt on vehicle underbody to 70 Nm/51.6 lbf. ft.
Repeat
this operation for the other shock absorber.
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Cut
pressure lines to size, ensuring clean cuts.
Right
pressure line approx. 150 cm/5 ft.
Left
pressure line approx. 350 cm/11.5 ft.
Note:
If
pressure lines are already cut to length, use correct line from shock
absorber to filler valve (different lengths for right and left).
Push
connecting parts onto pressure lines.
The
illustration shows the connecting parts already pushed onto the pressure
line, up to Model Year 1986.
1 Rubber seal
2 Metal sleeve
3 Pressure line
4 Union nut
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Insert
pressure lines with connecting parts in shock absorber and tighten union nuts
to 3 Nm/2.2.lbf. ft.
On
Vehicles as of Model Year '86:
Place
pressure line onto shock absorber.
Mount
retaining clips for pressure line of left shock absorber on fuel tank.
Mount
pressure line in retaining clips along tank vent hose and lay as far as hole
for filler valve.
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Mount
retaining clips for pressure line of right hand shock absorber to fuel tank.
Insert
pressure line and lay to hole for filler valve.
Insert
retaining clip for both pressure lines in hole in frame side member.
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Cut
pressure line to length for filler valve to be installed - ensure clean cuts.
Note:
If
pressure lines are already cut to length, use correct line from shock
absorber to filler valve (different lengths for right and left).
Insert
pressure lines with connecting parts in filler valve and tighten union nuts
to 3 Nm/2.2 lbf. ft.
On
Vehicles as of Model Year '86:
Place
pressure line onto filler valve.
Check
system for leaks.
Inflate
system to 800 kPa (8 bar)/116 psi and check all connections for leaks.
Regulate
air in shock absorber to 80 kPa (0.8 bar)/11.6 psi.
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Insert
filler valve with washer and rubber seal in vehicle underbody from
underneath.
On
Vehicles as of Model Year '86:
Insert
filler valve in vehicle underbody until it catches.
Fasten
both pressure lines with retaining clips.
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Lower
vehicle.
Fasten
filler valve with screw cap in load compartment with washer and hex nut.
On
vehicles with filler valve with snap-on cap, push on expanding ring, so that
filler valve stays fixed.
Inflate
system according to "Instructions for Filling the System".
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Fasten
sticker with air pressure details to tail gate as shown in illustration.
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Instructions
for Filling the System
(See
also information in Owner's Manual)
Prior
to loading, the unladen vehicle should be on a level surface and the empty
system should be filled to 80 kPa (0.8 bar)/11.6 psi.
Measure
the height of the rear bumper above the ground.
Deduct
5 cm/1.97 in. from this figure and note the new figure in the Owner's Manual.
If
this figure is not achieved when the vehicle is laden, increase pressure
until it is - do not exceed 500 kPa (5 bar)/72.5 psi.
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