Description

Mercedes-Benz E500, E320 2002 Technical Manual

I’ve seen too many guys try to wing it on the suspension of a Mercedes-Benz E500 or E320 without a proper technical manual. This Mercedes-Benz E500, E320 2002 Technical Manual is what the factory sent out to dealer techs in 2002. 41 pages, all about the Semi-Active Air Suspension (SAS) system. No filler. If you’re touching the suspension on one of these cars, you need this.

Don’t be fooled by cheap reprints. This is an original Mercedes-Benz USA training publication, dated 08-13-02. It’s not an aftermarket interpretation – it’s the actual OEM document used in the 319 HO SAS (ACB-ICC) training course. That matters when you’re torquing strut bolts or bleeding the system.

Semi-Active Air Suspension (SAS) – What You Get

The SAS system on these cars is a dual-control air suspension that handles both leveling and dampening. The manual dedicates the first several pages to SAS advantages and function. On page 3, you’ll find the full list: improved driving safety, ride height adaptation to load, dampening adaptation to road and driving style, speed-dependent lowering of the center of gravity, reduced aerodynamic drag, and driver control of vehicle level and dampening. That’s not marketing fluff – those are engineering targets you need to understand before you start diagnosing a sagging corner.

The advantages also include driver information like function indicator lamps in the switch and multi-function display warning messages. If you don’t know how those lamps behave during a fault, you’ll waste time chasing ghosts. The manual covers that.

For a deeper dive into the SAS system, see the Mercedes-Benz E500 E320 Semi-Active Air Suspension Manual. It’s the same content repackaged for technicians who prefer a separate binder.

ADS II: Why the Hydraulic Dampening Matters

ADS II is the hydraulic dampening half of the SAS system. Many DIYers focus on the air springs and neglect the dampening control. The manual explains how ADS II integrates with the SAS dual control – air suspension leveling and dampening work together. If you replace an air strut without checking the ADS II hydraulic circuit, you can end up with a car that rides like a pogo stick.

If you’ve ever had a Mercedes with a “Vehicle Rising” message stuck on the dash, you know the frustration. This manual walks you through the system interaction so you can isolate the problem to either the air side or the hydraulic side. No guesswork.

The manual covers the control unit logic, but if you need info on the ACC system in the W220, grab the Mercedes-Benz W220 2012 Technical Manual – ACC Hidden Menus. That’s a different beast.

Towing Blocks and Vehicle Level – Not Just a Switch

Towing blocks are a specific section in this manual – page references point to the procedure for safely raising the vehicle for towing without damaging the air suspension. Vehicle level notes tell you the acceptable ride height ranges and how to recalibrate after service. That’s something aftermarket manuals either skip or get wrong.

Vehicle level adjustments require the factory scan tool to zero the level sensors. The manual shows you the sequence. Miss that step, and the car will settle unevenly. I’ve seen it.

That’s a short but critical section. Don’t ignore it.

For diesel engine work on other models, the 2007 Unimog Technical Manual – BlueTec Diesel System is available, but that’s a completely different platform.

3 Key Areas Covered: SAS, ADS II, and Towing Procedures

The manual’s table of contents lists exactly three sections: Semi-Active Air Suspension (SAS), ADS II, Towing Blocks. That’s it. 41 pages of focused content on the systems that cause the most headaches on 2002 E500 and E320 models.

First, SAS – the air springs, level control, dampening adaptation. Second, ADS II – the hydraulic dampening module and its interaction with the air system. Third, towing blocks – how to use the service mode to raise the car without breaking the air springs. Not a single wasted page.

If you’re working on the transmission, you need the Manual Transmission fundamentals, but that’s separate from this suspension manual.

Similarly, for general manual transmission repair, consult Manual Transmission resources.

Source Authenticity: Factory OEM vs Aftermarket

When you buy this manual, you get a scan of the original Mercedes-Benz USA publication, copyright 2002. The copyright page explicitly states: “Reproduction by any means or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Mercedes-Benz USA, LLC.” That’s the real deal. Aftermarket manuals don’t carry that legal weight, and they often copy older revisions without the latest updates.

The manual states: “Always check for revised or updated information. To help avoid personal injury to you or others, and to avoid damage to the vehicle on which you are working, you must always refer to the latest Mercedes-Benz Technical Publication.” That’s a safety directive. Ignoring it is how you snap a line or lose a spring.

WIS stands for Workshop Information System – the factory database. This manual references it. Aftermarket manuals can’t.

Is this the full service manual for the E500 and E320?

No. It covers only the Semi-Active Air Suspension (SAS) system on 2002 models.

Can I use this to replace an air strut?

Yes, but you need the proper procedure for depressurizing the system and the torque specifications for the strut mounting bolts. This manual includes the step-by-step repair procedures and safety warnings. It also tells you how to use the factory scan tool to recalibrate ride height after replacement. Without that step, you risk damaging the new strut or getting an incorrect ride height that triggers warning messages. The vehicle level notes on the front air spring/strut (page 5) are critical – don’t skip them.

If you’re working on a 2002 Mercedes-Benz E500 or E320 with Semi-Active Air Suspension, stop guessing. Get the factory documentation. Access the Factory Manual from AutoRepairManuals and keep it on your bench. Your air springs will thank you.