SNIPPED FROM MY PREVIOUOS POST
So, the diagnosis - you knew we'd get here eventually, didn't you? Is that the computer finally realised that it doesn't have a valid suspension height calibration and commanded the system to loose air which it did until it couldn't lose any more at which point it stopped. Why did it remain inflated for several days before dropping again? Purely bad luck. The system likely decided to check itself again and gave up once it had fully deflated. Disconnect the electrical plug from the valve block and it can't do it again. The remedy is to input the codes from the new headlight into the computer and then recalibrate the height sensors but that is a job for George when he is back next week.
So, the saga continues. George (my tame mechanic) returned from his holiday and whisked the car down to a local, well respected, Merc specialist as his STAR system didn't have an option to code the headlight in. Merc specialist looked at him as if he was a bit simple (which he very definitely isn't) and said coding isn't necessary unless the new headlight is an after-market one - it was genuine with the same part number as the original. Their STAR system reported a communications error between the suspension control box and the valve block, which is what George's one reported.
Due to my bodging the suspension to keep it inflated there was some remedial wiring at the valve block needed so George decided to get a new connector and re-do the wiring. Having wired up the new connector he temporarily joined it to the original loom and hey-presto the fault cleared and dash message disappeared and the car re-inflated the suspension so he set about making the joints permanent by soldering and covering in heat shrink tubing. Great, thinks I, job done 😊 If only. The fault reappeared immediately and the suspension started to go down again 😬
A while later, we have re-inflated the suspension, tested and calibrated the ride height sensors and checked everything we can but the fault persists although the suspension is staying up. I'm off on holiday myself in a few days so decide to leave it and see what happens. Next morning the suspension is back down again so after a quick call to George I set about making up another temporary wiring loom using the old valve block connector and some wires to give me the power to open the valves in the block and manually inflate the suspension. It has now been inflated for five days and three hundred miles (mostly with 90kg of mobility scooter in the boot) with no issues except for the error message on the dash.
TBH, I have absolutely no idea what is going on but it has tried my patience beyond breaking point and the moment it is fixed it's going. No reprieve this time!