Remove/install front axle

AR33.10-P-0100N

Remove/install front axle

11.11.09

9.8.08

SWZ 140 589 00 33 00 for prying off upper ball joint added

Step 3

AR33.20-P-0500-01N

 

Remove/install

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

 Danger!

Risk of injury caused by body parts being jammed or crushed. Risk of injury to skin and eyes caused by brake fluid spraying out at high pressure when working on the SBC brake system

Deactivate SBC brake system using STAR DIAGNOSIS.

AS42.46-Z-0001-01A



When working on the front-end assembly, be careful not to scratch, mark or notch the surfaces of aluminum parts. Otherwise the service life of the parts will be affected



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Notes on Active Body Control suspension

AH32.50-P-0001-01N



If there is visible damage, e.g. crack formation or deformation of the front axle carrier (1), these parts must be replaced

 Installation

Only tighten nuts and bolts of chassis components when vehicle is in a ready-to-drive condition.

1

Deactivate SBC brake system

Model 230

 The following steps should be run through in STAR DIAGNOSIS:

Select menu item "SBC Sensotronic Brake Control"/"Deactivate 'SBC' system".

Then process all the individual steps from top to bottom.

2

Deactivate easy entry/exit function

Vehicles with memory package (driver seat, steering column, mirrors) code 275

 Otherwise the driver seat and steering wheel move to a different position, e.g. when the driver door is opened/closed. Damage to the upper frame can occur when the  holding device is installed.

 Deactivation is done using the buttons on the steering wheel in the "comfort" menu of the multifunction display; see operator's manual.

3

Turn front wheels to straight-ahead position and secure steering wheel with  holding device.

 Swivel sun visor to side and  insert retainer.

 On a disengaged steering coupling (25) the steering wheel should not be turned because the spiral contact coil will be destroyed.



*129589012100

4.1

Suction off oil from expansion reservoir of power steering pump

Model 230 without Active Body Control (ABC)



*210589007100

4.2

Extract oil from expansion reservoirs of tandem pump

Model 215, 220, 230 with code (487) Active Body Control (ABC)



*210589007100

5

Remove the front wheels



Remove/install wheels

AP40.10-P-4050Z

6

 Mount protective washers for brake cover plate

AR42.00-P-0100-01A



*220589013100

7

Disconnect right front axle multiple circuit junction connector, major assembly compartment (X62/6) and left front axle multiple circuit junction connector, major assembly compartment (X62/7)

 Detach connectors for damping valve unit and rpm sensor

8

Disconnect left front brake pad contact sensor connector (S10/1x1) and right front brake pad contact sensor connector (S10/2x1)

 Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

9

Detach brake lines from brake hose (39) and seal openings

 Seal off line terminals immediately with  stop plugs. The brake fluid expansion reservoir must not be allowed to run completely empty.

 Installation: The brake hoses (39) must not be twisted after being tightened (danger of cracking).

 When loosening or tightening the brake line on the brake hose (39), take care not to twist its bracket. When undoing and tightening the brake line, use an open end wrench to counterhold the brake hose's (39) double edge.



*129589009100



*000589750300



*BA42.10-P-1001-04A



Brake fluid notes

AH42.50-P-0001-01A



Notes on installing brake hoses

AH42.10-P-9406-01A

10.1

Remove lower engine compartment paneling

Model 215, 220 with gasoline engine

AR61.20-P-1105M

Model 230

AR61.20-P-1105R

10.2

Remove bottom sections of soundproofing

Model 220 with diesel engine

AR94.30-P-5300M

11.1

Detach front diagonal struts

Model 230

 Installation: The bolts on the diagonal struts may only be tightened when the vehicle is resting with its wheels on the ground.



*BA61.10-P-1011-01C

11.2

Disconnect bracket for pressure lines (54a, 54b) from front axle carrier (1)

Model 215, 220

 Tie up pressure line to the side.

12.1

Remove heat shield (2c) and bracket (1n)

Model 230

12.2

Detach right rear pressure supply valve unit (52) from front subframe (1)

Model 215, 220

 Tie up pressure supply valve unit (52) on one side.

13

Disconnect bracket for pressure line (54c) of compressed-air supply valve unit (52) from front axle carrier (1)

Model 215, 220

 Tie up pressure line to the side.

14

Press follower joints (8) out of steering knuckles (5)

AR33.20-P-0500-01N



*BA33.20-P-1007-01F



*BA33.20-P-1018-01A



*210589046300



*202589023300



*140589003300

15

Remove bolt (25a) of steering coupling (25) at lower steering shaft (80a)

 Installation: Replace locking plate (25f) with self-locking nut.



*BA46.10-P-1001-01E

16

Plug suitable tool into the bore of the steering coupling (25) or into the bore of the lower steering shaft (80a) and pull the lower steering shaft (80a) upwards out of the steering coupling (25)

 Do not counterhold at the rubber boot or at the plastic temperature protection disk for the lower steering shaft (80a). Do not use force (hammer blows, excessive leverage) as the lower steering shaft is sensitive to lateral forces.

 Installation: Insert lower steering shaft (80a) all the way into the steering coupling (25); pay attention to the studs of the steering coupling (25) while doing so and the groove of the lower steering shaft (80a) (arrows).

17

Disconnect speed-sensitive power steering plug (3)

18.1

Remove bolts (40c) on suspension struts (40)

Model 215, 220

 Installation: Bolts (40c) after tightening must lie flush with the suspension strut (40) or be slightly recessed.



*BA32.25-P-1002-04B

18.2

Undo nuts of suspension strut (40) on spring control arms and push suspension strut (40) out of the spring control arms

Model 230



*BA32.25-P-1007-04B



*230589003300



*140589006300

19

Raise engine until the front engine mounts are completely relieved of load.

Model 215, 230 and 220 except 220.028/ 128

AR33.10-P-0100-01R

Model 220.028/ 128

AR01.10-P-7500-03M

Load regulator (engine hoist) gotis://H_00.12_04.0

Additional hanger for load regulator (engine hoist)

gotis://H_00.12_08.0

20

Remove bolts (1g) and remove engine mount from front axle carrier (1)



*BA22.10-P-1001-01L



*BA22.10-P-1002-03A



*BA22.10-P-1001-03H

21

Prop front axle carrier (1) using transmission platform and transmission jack

Transmission platform

gotis://A_25/35/49_02.0

AR33.10-P-0100-03I

22

Remove bolts (1f) from front axle carrier (1).

 The bolts (1f) are self-tapping, so the following points must be observed:

 Never recut the thread in the longitudinal member

 Replace bolts

 Use only original bolts (4 x)

 Do not attach bolts at an angle
when screwing in

 Do not use an impact bolt tightener

 Observe tightening torque

 Installation: Model 220.Before tightening the bolts (1f) center the front axle carrier (1) with a  drift (a, 14,8 mm dia.) on the right and left. After this, insert rubber plugs.



*220589001500



*BA33.10-P-1003-01A



Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

23

Detach high-pressure expansion hose (30i) and return line (30f) from steering gear

 If necessary lower the front axle slightly, in the process do not tension the lines in order to preclude irreparable damage.

  Seal off line connections using plugs.



*129589009100



*BA46.20-P-1002-01E



*BA46.20-P-1001-01E



*BA46.20-P-1006-01E

24

Remove heat shield (2c) from front axle carrier (1)

Model 215, 220

25

Lower front axle carrier (1)

26

Detach upper transverse control arm (6)

If necessary:

Model 215, 220

AR33.20-P-0500I

Model 230

AR33.20-P-0500R

27

Detach suspension strut (40)

If necessary:

Model 215, 220

AR32.25-P-1017N

Model 230 with code (487) Active Body Control (ABC)

AR32.25-P-1017R

Model 230 without Active Body Control (ABC)

AR32.25-P-1017TS



Checking

28

Check front axle carrier (1) for signs of damage and if damage determined replace parts

29

Install in the reverse order

30.1

Fill tandem pump and bleed

Model 215, 220, 230 with code (487) Active Body Control (ABC)

AR46.30-P-0010N

30.2

Fill power steering pump and bleed

Model 230 without Active Body Control (ABC)

AR46.30-P-0010B

31.1

Bleed brake system with STAR DIAGNOSIS

Model 230

AR42.10-P-0012R

 When performing the bleeding operation always observe the instructions in the document "Bleeding brake system using STAR DIAGNOSIS".

 The following steps should be run through in STAR DIAGNOSIS:

Select menu item "initial startup after repair"/"after opening or exchanging one or more brake hoses".

Then process all the individual steps from top to bottom.

 Danger!

Risk of accident when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work

Before starting engine, actuate brake pedal several times until the pressure is built up and maintained in the brake system.

AS42.50-Z-0002-01A

31.2

Bleed brake system

Model 215, 220

AR42.10-P-0010I

32

Perform a wheel alignment check

Model 215, 220

AR40.20-P-0200I

Model 230

AR40.20-P-0200R

Number

Designation

Engine
113.960
in model 215

Engine
113.991
in model
215

Engine
137.970
in model 215

BA22.10-P-1001-01L

Bolt, front engine mount to front axle carrier

Nm

35

35

35

Number

Designation

Engine
113.986
in model 215

Engine
275.950/
980
in model 215

BA22.10-P-1001-01L

Bolt, front engine mount to front axle carrier

Nm

35

35

Number

Designation

Model
230 except model 230.476/477/479

Model 230.476/477/479

BA22.10-P-1001-03H

Bolt, front engine mount to front axle carrier

Nm

35

35

Number

Designation

Model
220

BA22.10-P-1002-03A

Front engine mount on front axle carrier

Nm

35

Number

Designation

Model
215

Model
220.025/026/028/063/
065/067/070/073/074/
075/125/126/128/163/
165/167/170/173/174/
175/176/178/179

Model
230 except code P99

BA32.25-P-1002-04B

Bolt, front suspension strut to spring control arm

Nm

20

20

-

BA32.25-P-1007-04B

Nut, front suspension strut to spring control arm

Nm

-

-

110

Number

Designation

Model
215

Model
220

Model
230

BA33.10-P-1003-01A

Bolt, front axle carrier to front end

Nm

100

100

100

Number

Designation

Model
215

Model
230 except code P99

BA33.20-P-1018-01A

Self-locking nut, upper wishbone follower joint to steering knuckle

Stage 1

Nm

20

20

Stage 2

°

90

90

Number

Designation

Model
220
with Code
Z07

Model
220 without code Z07 except model 220.08/18 /8

Model 220.875/
878

BA33.20-P-1007-01F

Self-locking nut, upper wishbone follower joint to steering knuckle

Stage 1

Nm

20

20

20

Stage 2

°

90

90

90

Number

Designation

Model
215

Model
220

Model
230 except code P99

BA42.10-P-1001-04A

Brake pipe to brake hose

Nm

14

14

14

Number

Designation

Model
215

Model
220.025/026/
028/063/065/
067/070/073/
074/075/125/
126/128/163/
165/167/170/
173/174/175/
176/178/179/
875/878

Model
230

BA46.10-P-1001-01E

Bolt, steering coupling to steering shaft

Stage 1

Nm

30

30

30

Stage 2

°

-

-

-

Number

Designation

Model
215

Model
220.025/026/
028/063/065/
067/070/073/
074/075/125/
126/128/163/
165/167/170/
173/174/175/
176/178/179/
875/878

Model
230

BA46.20-P-1001-01E

Return pipe to rack-and-pinion steering

Nm

45

45

-

BA46.20-P-1002-01E

High-pressure stretch hose to rack-and-pinion steering

Nm

40

40

-

BA46.20-P-1006-01E

Bolt on clamp plate, high-pressure line / return line to rack-and-pinion steering

Nm

-

-

18

Number

Designation

Model
230

BA61.10-P-1011-01C

Self-locking bolt, front diagonal strut to frame floor/front axle carrier

Nm

70