Remove/install rack-and-pinion steering

AR46.20-P-0600EW

Remove/install rack-and-pinion steering

22.08.2018

Model

204.9, 212

except code 211 (Direct-Steer system)

Shown on vehicle with ENGINE 272

8

Retaining plate

10c

Screw

15

Screw

9

Clamping plate

11

Front axle carrier

16

Bracket

10

Rack-and-pinion steering

12

Screw

Y10

Speed-sensitive power steering solenoid valve

10a

Screw

13

Power steering oil line

10b

Bolts

14

Power steering oil line

 Warning

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

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

AS00.00-Z-0013-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Evaluating steering gear when repairing accident vehicles

AH46.20-P-9409-01A

 

Remove/install

1

Deactivate easy entry/exit function

Model 204.9, 212
with code 275 (Memory package)
except code 211 (Direct-Steer system)

2

Turn steering wheel into center position (front wheels in straight-ahead position) and fix in position with retaining device


The steering wheel must not be turned when detaching steering coupling.
Otherwise the clock spring contact will be destroyed.

 Retainer device

*129589012100

3

Open engine hood

Model 204.9, 212
except code 211 (Direct-Steer system)

Model 212

AR88.40-P-1000EW

4.1

Remove the left engine intake air duct

Engine 272, 273

4.2

Remove upper engine cover

Engine 642, 651

 Installation: Ignition switched off.

4.3

Remove front engine cover

Model 212 with engine 156
except code 211 (Direct-Steer system)


Do not tilt front engine cover, but lift it off vertically toward top.
Otherwise the retaining lug could break off.

5

Extract oil from power steering expansion reservoir


Before opening the hydraulic system, thoroughly clean the area surrounding the separation point.
Even the smallest dirt particles, introduced into the hydraulic components, can lead to malfunctions and a total failure of the hydraulic system.

 Hand pump

*210589007100

6

Remove the front wheels



Model 204.9

AP40.10-P-4050CW



Model 212

AP40.10-P-4050EW

7.1

Remove center and rear section of lower engine compartment paneling

Model 212 with gasoline engine

AR61.20-P-1105EW

7.2

Remove center and rear bottom sections of soundproofing

MODEL 212 with diesel engine

AR94.30-P-5300EW

7.3

Detach lower engine compartment paneling

Model 204.9

AR61.20-P-1105CY

8

Remove tie rods from steering knuckles

AR46.40-P-0200-02CW

 Model 204.9, 212
except code 211 (Direct-Steer system)Self-locking nut, tie rod to steering knuckle

*BA46.40-P-1001-01N

 Thrust piece

*171589003400

 Puller

*221589003300

 Puller

*221589053300

 Press

*163589034300

9

Detach steering coupling from rack-and-pinion steering (10)

Model 204.9

AR46.10-P-8000CW

Model 212

AR46.10-P-8000EW

 Installation: Replace self-locking nut.

 Model 204.9, 212
except code 211 (Direct-Steer system)Nut/bolt, steering coupling to steering shaft

*BA46.10-P-1001-01M

10

Disconnect electrical connector from speed-sensitive power steering (Y10)

Model 204.9, 212
with code 213 (Speed-sensitive power steering)
except code 211 (Direct-Steer system)

 If necessary, detach cable tie from electrical line.

11

Remove bolt (12) from rack-and-pinion steering (10)

 Model 204.9, 212
except code 211 (Direct-Steer system)Bolt, clamp plate, high-pressure line / return line to rack-and-pinion steering control head

*BA46.20-P-1003-01N

12

Remove bolt (15) and remove bracket (16) from rack-and-pinion steering (10)

 Model 204.9
except code 211 (Direct-Steer system)High pressure and low-pressure hoses to rack-and-pinion steering housing

*BA46.20-P-1004-01N

13

Pry clamping plate (9) off rack-and-pinion steering (10) and pull out power steering oil lines (13, 14)

 Place oil lines for power steering (13, 14) to one side and seal all openings using  stop plugs.

 Installation: Replace O-rings.

 Record plug

*129589009100

14

Support rack-and-pinion steering (10) and secure to prevent it from falling down

15

Remove bolt (10c) from additional bracket or additional mounting of rack-and-pinion steering (10) to front axle carrier (11)

 Model 204.9
except code 211 (Direct-Steer system)Bolt, steering gear rack-and-pinion steering to front axle carrier

*BA46.20-P-1010-01N

16

Remove bolts (10a, 10b)

 Installation: Replace bolts (10a, 10b).

 Fastening, rack-and-pinion steering to front axle carrier

*BA46.20-P-1001-01N

 Bolt, retaining plate for rack-and-pinion steering to front axle carrier

*BA46.20-P-1002-01N

17

Take out retaining plate (8) with rack-and-pinion steering (10)

18

Install in the reverse order

19

Fill power steering pump and bleed

Model 204.9

AR46.30-P-0010CW

Model 212

AR46.30-P-0010EW

20

Check front axle toe and adjust if necessary

Model 204.9

AR40.20-P-0200CW

Model 212

AR40.20-P-0200EW

 After installation of new parts.

 Steering shaft

Number

Designation

Model 204

Model 212

BA46.10-P-1001-01M

Nut/bolt, steering coupling to steering shaft

Nm

30

30

 Steering gear

Number

Designation

Model 204 (except 204.08/09/28/29/38/904/937/98/99)
except code 211 (Direct-Steer system)

Model 204.08/09/28/29/38/904/937/98/99

BA46.20-P-1001-01N

Fastening, rack-and-pinion steering to front axle carrier

Stage 1

Nm

70

100

Stage 2

°

90

90

 Steering gear

Number

Designation

Model 212 (except 212.067/08/090/091/093/094/097/099/267/28/291/293/294/297/299)
except code 211 (Direct-Steer system)

Model 212.067/08/090/091/093/094/097/099/267/28/291/293/294/297/299

BA46.20-P-1001-01N

Fastening, rack-and-pinion steering to front axle carrier

Stage 1

Nm

70

100

Stage 2

°

90

90

 Steering gear

Number

Designation

Model 204 (except 204.08/09/28/29/38/904/937/98/99)
except code 211 (Direct-Steer system)

Model 204.08/09/28/29/38/904/937/98/99

BA46.20-P-1002-01N

Bolt, retaining plate for rack-and-pinion steering to front axle carrier

M12

Nm

110

110

 Steering gear

Number

Designation

Model 212 (except 212.067/08/090/091/093/094/097/099/267/28/291/293/294/297/299)
except code 211 (Direct-Steer system)

Model 212.067/08/090/091/093/094/097/099/267/28/291/293/294/297/299

BA46.20-P-1002-01N

Bolt, retaining plate for rack-and-pinion steering to front axle carrier

M12

Nm

110

110

 Steering gear

Number

Designation

Model 204 (except 204.08/09/28/29/38/904/937/98/99)
except code 211 (Direct-Steer system)

Model 204.08/09/28/29/38/904/937/98/99

BA46.20-P-1003-01N

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

Nm

21

21

 Steering gear

Number

Designation

Model 212 (except 212.067/08/090/091/093/094/097/099/267/28/291/293/294/297/299)
except code 211 (Direct-Steer system)

Model 212.067/08/090/091/093/094/097/099/267/28/291/293/294/297/299

BA46.20-P-1003-01N

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

Nm

21

21

 Steering gear

Number

Designation

Model 204 (except 204.08/09/28/29/38/904/937/98/99)
except code 211 (Direct-Steer system)

Model 204.08/09/28/29/38/904/937/98/99

BA46.20-P-1004-01N

High pressure and low-pressure hoses to rack-and-pinion steering housing

M6

Nm

10

10

 Steering gear

Number

Designation

Model 204 (except 204.08/09/28/29/38/904/937/98/99)
except code 211 (Direct-Steer system)

Model 204.08/09/28/29/38/904/937/98/99

BA46.20-P-1010-01N

Bolt, steering gear rack-and-pinion steering to front axle carrier

M8

Nm

28

28

 Tie rod

Number

Designation

Model 204

Model 212

BA46.40-P-1001-01N

Self-locking nut, tie rod to steering knuckle

Stage 1

Nm

50

50

Stage 2

°

60

90