Arnott C-2278 User manual

1REV 2 11/18/2013 C-2278
C-2278
ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
Arnott®is committed to the quality of its products. If you have a question or problem with any Arnott product,
please contact Arnott by calling 800-251-8993 during normal business hours or email [e-mail]
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 suspension system prior to disassembly. 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
21-6807 1 ARNOTT FRONT COIL SPRING CONVERSION
21-6808 1 ARNOTT REAR COIL SPRING CONVERSION
21-6838 1 ACCESSORY KIT
Congratulations on your purchase of an Arnott®air suspension product. We at Arnott Incorporated are proud
to offer a high quality product at the industry’s most competitive pricing.Thank you for your condence in us
and our product.
Proper installation is essential to experience and appreciate the benets of this system. Please take a moment
to review these installation instructions before you begin to install these components on your vehicle.The
removal and installation of air suspension products should only be performed by a fully qualied, ASE
Certied, professional.
It is equally important to be aware of all necessary safety measures while installing your new Air Suspension
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™"

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FRONT AIR STRUT REMOVAL
1. SET THE STEERINGTO STRAIGHT AHEAD.
2. RAISE THE VEHICLE.
3. REMOVE THE FRONT WHEELS. (FIGURE 10-1)
FIGURE 10-1
GENERAL INFORMATION:
Reading this manual signies your agreement to the terms of the general release, waiver of liability, and hold harmless agreement,
the full text of which is available at www.arnottinc.com.
• Not to be stored below 5oF (-15oC) and above 122oF (50oC).
• Avoid damage to air lines and cables.
• Removal and installation is only to be performed by fully qualied personnel.
• Use car manufacturer’s diagnostic software.
CAUTION: Damage to the vehicle and air suspension system can be incurred if work is carried out in a manner other than specied
in the instructions or in a different sequence.
To avoid the possibility of short circuits while working with electric components consult your owner's manual on how to
disconnect your battery.
Consult your vehicle owner's manual, service manual, or car dealer for the correct jacking points on your vehicle and for
additional care, safety and maintenance instructions. Under no circumstances should any work be completed underneath
the vehicle if it is not adequately supported, as serious injuries and death can occur.
These air springs contain a solenoid valve. Once inated, only the “Mercedes DAS Star” diagnostic computer can deate
the air springs.

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C-2278
ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 10-2
FIGURE 10-3
5. SEPARATE THE BALL JOINT FROMTHE SPINDLE ASSEMBLY. (FIGURE 10-3)
4. LOCATE AND REMOVE THE UPPER CONTROL ARM BALL JOINT NUT. (FIGURE 10-2)
6. REMOVE THE SENSOR LINES FROM BRACKETS. (FIGURE 10-4)
FIGURE 10-4

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 10-5
FIGURE 10-6
8. DISCONNECT THE STRUT’S ELECTRICAL PLUG LOCATED BEHIND THE INNER FENDER WELL. (FIGURE 10-6)
7. REMOVE THE INNER FENDER WELL SCREWS. (FIGURE 10-5)
9. LOOSEN BUT DO NOT REMOVE THE LOWER STRUT MOUNTING BOLT. (FIGURE 10-7)
FIGURE 10-7

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 10-8
FIGURE 10-9
11. UNPLUG THE ELECTRICAL CONNECTOR. (FIGURE 10-9)
10. REMOVE THE AIR LINE. (FIGURE 10-8)
12. REMOVE THE THREE TOP MOUNTING BOLTS. (FIGURE 10-10)
FIGURE 10-10

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 10-11
FIGURE 10-12
14. REMOVE THE STRUT ASSEMBLY FROM THE VEHICLE. (FIGURE 10-12)
13. REMOVE THE LOWER STRUT MOUNTING BOLT. (FIGURE 10-11)
15. AIR STRUT REMOVAL COMPLETE.

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 20-1
FIGURE 20-2
2. POSITION THE BOTTOM MOUNT ONTOTHE CONTROL ARM. (FIGURE 20-2)
FRONT AIR STRUT INSTALLATION
1. INSTALL THE STRUT INTOTHE UPPER MOUNT CAVITY. (FIGURE 20-1)
3. INSTALL THE BOTTOM MOUNT NUT AND BOLT. (FIGURE 20-3)
FIGURE 20-3
Tighten all nuts and bolts to manufacturer's specications during the installation process.

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 20-4
FIGURE 20-5
5. INSTALL THE BALL JOINT NUT. (FIGURE 20-5)
4. RECONNECTTHE BALL JOINTTO SPINDLE ASSEMBLY. (FIGURE 20-4)
6. INSTALL THE THREE TOP MOUNTING NUTS. (FIGURE 20-6)
7. FRONT STRUT INSTALLATION COMPLETE.
FIGURE 20-6

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 30-1
FIGURE 30-2
2. REMOVETHE BOLTS FROM FENDER WELL. (FIGURE 30-2)
REAR AIR SPRING REMOVAL
1. REMOVETHE REAR WHEELS. (FIGURE 30-1)
3. REMOVETHE PUSH PINS FROM FENDER WELLTO EXPOSE THE SENSOR JUNCTION BLOCK. (FIGURE 30-3)
FIGURE 30-3

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 30-4
5. REMOVE THE SENSOR LINES FROM THE BRACKETS. (FIGURE 30-5)
4. MARK THE CONNECTIONSTO ENSURE PROPER PLACEMENT IN REASSEMBLY, REMOVE RETAINING CLIP
AND UNPLUG SENSOR LINES. (FIGURE 30-4)
FIGURE 30-5

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 30-6
FIGURE 30-7
7. REMOVE THE LOWER SHOCK BOLTS. (FIGURE 30-7)
6. REMOVE THE AIR SPRING BOLTS FROM THE LOWER CONTROL ARMS. (FIGURE 30-6)
8. REMOVE THE MOUNTING NUT FROMTHE AIR BLOCK. CLEARLY MARKTHE AIRLINES ONTHE AIR
DISTRIBUTATION BLOCK BEFORE DISCONNECTING. (FIGURE 30-8)
FIGURE 30-8

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 30-9
10. SUPPORT EXHAUST, LOOSEN AND REMOVE EXHAUST FLANGE BOLTS. (FIGURE 30-10)
9. AFTERTHE AIR LINES ARE REMOVED, UNPLUGTHE AIR SPRINGS VALVE WIRING. (FIGURE 30-9)
FIGURE 30-10

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 30-11
11. WITHTHE EXHAUST STILL SUPPORTED, REMOVETHE RUBBER HANGERS.THEN REMOVETHE EXHAUST.
(FIGURE 30-11)
12. REMOVETHE DRIVESHAFT SAFETY BAR, ANDTHETWO-PIECE HEAT SHEILDTO EXPOSETHE
DRIVE SHAFT CARRIER BEARING. (FIGURE 30-12)
FIGURE 30-12

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 30-13
FIGURE 30-14
14. REMOVETHE REAR DRIVESHAFT BOLTS. (FIGURE 30-14)
13. REMOVETHETWO BOLTS HOLDINGTHE CARRIER BEARING.CAREFULLY LOWER. (FIGURE 30-13)
15. SLIDE THE DRIVESHAFTTOWARDTHE FRONT OF VEHICLE AND REMOVE. (FIGURE 30-15)
FIGURE 30-15

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 30-16
FIGURE 30-17
17. LOOSEN BOLTS AND REMOVE BOTH REAR ROCK GUARDS. (FIGURE 30-17)
16. LOOSEN BOLTS AND REMOVE THE REAR HEAT SHIELDS. (FIGURE 30-16)
18. REMOVE CALIPER CLIPS, ANDTHEN REMOVE BOLTS FROM BRAKE PAD WEAR SENSORS. (FIGURE 30-18)
FIGURE 30-18

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 30-19
FIGURE 30-20
20. REMOVE THE CAPS FROM THE CALIPER MOUNTING BOLTS, LOOSEN AND REMOVE BOLTS. (FIGURE 30-20)
19. UNPLUGTHE BRAKE PAD WEAR SENSORS. (FIGURE 30-19)
21. REMOVE CALIPERS, AND SUSPEND WITH CABLETIES. (FIGURE 30-21)
FIGURE 30-21

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 30-22
FIGURE 30-23
23. THE REAR CROSSMEMBER BOLT POINTS. (FIGURE 30-23)
22. LOOSEN FILLER NECK CLAMP, AND REMOVE GASTANK FILLER HOSE. (FIGURE 30-22)
24. LOWERTHE VEHICLE AND POSITION JACK STANDS TO SUPPORT THE REAR SUB FRAME. REMOVETHE FOUR
(4) BOLTS HOLDING THE SUB FRAME TO THE VEHICLE. (FIGURE 30-24)
FIGURE 30-24
FIRE HAZARD: Use extreme caution when working on, or around, fuel tank as gas fumes may be present.
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.

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 30-25
FIGURE 30-26
26. LOCATE, LOOSEN, AND REMOVETHE SWAYBAR BOLTS. (FIGURE 30-26)
25. SUPPORT CROSSMEMBER ASSEMBLY ON JACK STANDS, AND RAISE VEHICLETO ACCESS THE AIR SPRINGS.
(FIGURE 30-25)
27. RAISE SWAY BARTOWARDS REAR OF VEHICLE. (FIGURE 30-27)
FIGURE 30-27

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 30-28
FIGURE 30-29
29. REMOVE BOTH AIR SPRINGS AND RESERVOIRS. (FIGURE 30-29)
28. LOOSEN, AND REMOVETHE BOLTS FORTHE AIR RESEVOIRS. (FIGURE 30-28)
30. WITHTHE AIR SPRINGS REMOVED, REMOVETHE AIR LINES FROMTHETOP MOUNT OFTHE AIR SPRINGS.
(FIGURE 30-30)
FIGURE 30-30

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ARNOTT COIL SPRING CONVERSION KIT
FOR 2002-2009
MERCEDES-BENZ E-CLASS
FIGURE 30-31
FIGURE 30-32
32. REMOVETHE D-RINGTIE DOWN ONTHETRUNK FLOOR AND PULL BACKTHE CARPETTO ACCESSTHE REAR
TOP SHOCK MOUNT. (FIGURE 30-32)
31. TO REMOVETHE REAR SHOCKS, GAIN ACCESSTOTHETRUNK AND PULL HANDLESTO FOLD THE REAR
SEATS DOWN. (FIGURE 30-31)
33. REMOVETHETOP NUTS, AND PULL THE SHOCKS FROM UNDERNEATHTHE VEHICLE. (FIGURE 30-33)
FIGURE 30-33
34. AIR SPRING AND SHOCK REMOVAL IS COMPLETE.