bpw -service instructions

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BPW Air suspensions

– Visual inspection. Check all component parts for damage and wear.

1 Check condition of air bags.

2 Check air suspension level valves for condition, seal�tightness and general tightness.

3 Check shock absorber fastening for tightness.Tightening torques with a torque wrench:

M 24 M = 420 Nm (390�460 Nm)for aluminium hanger brackets M = 320 Nm (300�350 Nm)

4 Check spring mounting kit for tightness.Tightening torques with a torque wrench:

M 22 M = 550 Nm (510�600 Nm) 2)

M 24 M = 650 Nm (605�715 Nm)

5 Check spring pivot bolts for tightness.Tightening torques with a torque wrench:hanger brackets up to 07/2001: M 30 M = 750 Nm (700�825 Nm)hanger brackets from 08/2001: M 30 M = 900 Nm (840�990 Nm)channel cross member: M 30 M = 900 Nm (840�990 Nm)

6 Check air bag fastening for tightness.Tightening torques with a torque wrench:

M 12 M = 66 NmM 16 M = 230 Nm

7 Check axle lift for tightness.Tightening torques with a torque wrench:supporting arm M 16 M = 230 Nmcylinder M 16 M = 180 � 210 Nm

8 Check strap. Check condition and fastening.1) under extreme conditions, more frequently.2) When mounting new spring mounting kit components for Airlight II:

Tightening torque: M 22 M = 550 Nm + 90° angle tightening3) for use outside Europe

Valid: 01.11.2003

Maintenance work after expiry of the warranty periodOOvveerrvviieewwFor detailed description see pages 34 - 39Visual checks or maintenance work during the warranty period, see pages 9 � 11

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2 Air installation circuit– After expiry of the warranty period:

Recommended half�yearly, after 1 year off�road or 2 years on�road outside EuropeRecommended annually, after 3 years off�road, 5 or 8 years on�road –

Check air installation valves and line connections for firm seating, damage andseal�tightness. Check valve linkage andfastenings (arrows) for damage and tight�ness. The length of the valve lever andpermissible angular positions on the valvelinkage are shown in the illustration below.

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Air levelling valve

– Visual inspection– After expiry of the warranty period:


Check all component parts for wear and damage.

1 Air bags– After expiry of the warranty period:


Check air bags for external damage (sur�face cracking, abrasion, crease formation, trapped foreign bodies etc.).Replace air bags in the event of damage.

Safety noticeNo welding should be carried out on steelparts of air bags and pressure vessel! Theair suspension should only be filled withcompressed air when mounted or when themechanical height limit has been reached! Danger of injury!

BPW Air suspensions

Maintenance work after expiry of the warranty periodVisual checks or maintenance work during the warranty period, see pages 9 � 11

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5 Spring pivot bolts– After expiry of the warranty period:


Check bushes � move vehicle backward andforward slightly with the brake applied, ormove rolled spring ends with the aid of alever. No play should be present in the rolledspring end when doing so. If the fastening isloose the spring pivot bolt may be damaged. � Check the wear washers in the

hanger bracket.� Check the M 30 lock nut on the spring

pivot bolt for tightness.Tightening torque with a torque wrench:Air suspension hanger bracketsup to 07/2001 M 30 M = 750 Nm (700�825 Nm)from 08/2001 M 30 M = 900 Nm (840�990 Nm)Channel cross member

M 30 M = 900 Nm (840�990 Nm)The serviceable life of the rubber/ steelbush is dependent on the tightness of theinner steel bushing.

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Single�sided lift Two�sided lift

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spring pivot bolt spring pivot bolt

Spring pivot bolt bearing with axle lift

3 Shock absorber fastening– After expiry of the warranty period:


Check lower and upper shock absorberfastening for tightness.Tightening torques with a torque wrench:

M 24 M = 420 Nm (390�460 Nm)In the case of alloy hanger bracket:

M 24 M = 320 Nm (300�350 Nm)

4 Spring mounting kit– After expiry of the warranty period:


Check lock nuts of spring U�bolts fortightness. If loose, tighten nuts alternatelya little at a time. No welding should beperformed on the trailing arm spring!Tightening torques with a torque wrench:

M 22 M = 550 Nm (510�605 Nm)M 24 M = 650 Nm (605�715 Nm)

When mounting new spring mounting kitcomponents for Airlight II:Tightening torque:M 22 M = 550 Nm + 90° angle tightening

BPW Air suspensions


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8 Check straps– After expiry of the warranty period:


Examine check straps and attachment.Replace if necessary.

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7 Axle lift– After expiry of the warranty period:


Check the M16 lock nuts on the lever armfixing and diaphragm cylinder to make surethey are tight. Tighten with a torquewrench if necessary.Tightening torques with a torque wrench:supporting arm M 16 M= 230 Nmcylinder M 16 M= 180 � 210 NmCheck for wear on the bump stop on thelever arm or the stop for the double�sided lift. Make sure they are secure.

M 12 M= 66 Nm

BPW Air suspensions


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6 Air bag fastenings– After expiry of the warranty period:


Check air bag fixing screws or nuts for tightness.Tightening torques with a torque wrench:

M 12 M= 66 NmM 16 M= 230 Nm

bpw -service instructions

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