31 11 506 Lower/raise front axle support (universal lifter) (PHEV)

Special tools required:

31 4 170
31 5 250
00 2 030
31 5 255
31 5 256

WARNING: High-voltage system - risk of serious injury or death.

Observe SAFETY INFORMATION for handling hybrid cars.

WARNING:

Risk of injury!

Failure to comply with the following instructions may result in the vehicle slipping off the vehicle hoist and critically injuring other persons.

When supporting components, make sure that:

the vehicle can no longer be raised or lowered
the vehicle does not lift off the locating plates on the vehicle hoist.

IMPORTANT:

Before lowering/removing front axle support:

Observe SAFETY INFORMATION for raising the vehicle!

In order to avoid damage to vehicle hoist, perform weight compensation on vehicle!

Load spring strut domes with sand bags.

WARNING: Secure engine in INSTALLATION POSITION with special tool to prevent it from falling down.
Before lowering the front axle support, it is essential that the STEERING SHAFT on the steering box is unfastened!
If this is not carried out, the bulkhead steering shaft bearing will be damaged!

Necessary preliminary tasks:

Disconnect BATTERY NEGATIVE LEAD .
Remove microfilter housing cover on left and right. See REMOVING LEFT MICROFILTER HOUSING COVER and REMOVING RIGHT MICROFILTER HOUSING COVER .
Remove FAN COWL .
Remove FRONT WHEELS .
Remove underbody protection at front and rear. See REMOVING UNDERBODY PROTECTION (FRONT) and REMOVING REAR ENGINE UNDERCOVER .
Remove steering box cover at top left and right. See REMOVING TOP LEFT STEERING BOX COVER and REMOVING TOP RIGHT STEERING BOX COVER .

Release screws (1) from transmission oil cooler (2).

Tightening torque 17 22 3AZ .

Fig 1: Identifying Transmission Oil Cooler Screws

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Release 3 screws (1) on left underbody panelling (2).

Installation note:

Risk of damage!

Risk of trapping and damage to underbody panelling (3).

Fig 2: Identifying Left Underbody Paneling Screws

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IMPORTANT: Use special tool to avoid preliminary damage to ball joint in upper wishbone and the associated necessary removal of swivel bearing.

Press plug on left and right out of spring strut dome.

Secure swivel bearing (1) on left and right with special tool 31 4 170 in installation position.

Fig 3: Identifying Swivel Bearing And Special Tool (31 4 170)

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Slacken nut (1).

Tightening torque 31 35 2AZ .

Release anti-roll bar link (2) from anti-roll bar.

Installation note:

Replace nut (1).

Fig 4: Identifying Anti-Roll Bar Link And Nut

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Disconnect connector (1).

Release connector from holder for front bottom left wheel arch cover (2).

Release cable from front axle support.

NOTE: For a better general view, the bottom left wheel arch cover is disassembled.

Fig 5: Identifying Holder And Connector

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Loosen screw (1) of coolant lines (2) on the left mounting of the engine mount.

Fig 6: Identifying Coolant Lines And Screw

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Release screw (1).

Release cable channel (2) from front axle support.

Fig 7: Identifying Cable Channel And Screw

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Release connectors (2 and 3) from EPS steering gear.

Fig 8: Identifying EPS Steering Gear Connectors

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Remove LOWER WISHBONE FROM SPRING STRUT HOLDER .

Engage special tool31 5 250 with a 2nd person helping completely on workshop jack 00 2 030 .

Insert special tools31 5 255 in telescopic supports of a profile rail pair.

Insert special tools 31 5 256 in telescopic supports of other profile rail pair.

NOTE: In a profile rail pair, two profile rails are connected to one another by gearing.

Fig 9: Inserting Special Tools (31 5 255) In Profile Rail Pair Telescopic Supports

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Mounting point (1) for special tool 31 5 250 on right hand side.

Fig 10: Identifying Special Tool (31 5 250) Mounting Point

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Align special tools 31 5 255 and 31 5 256 to front axle support.

Support front axle support by operating workshop jack 00 2 030 .

IMPORTANT: The center of gravity of the front axle must lie in the middle above the workshop jack.

Fig 11: Aligning Special Tools (31 5 255) And (31 5 256) To Front Axle Support

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Release screws (1, 2).

Tightening torque 31 10 1AZ .

Lower front axle support by no more than 10 cm.

Installation note:

Check threads for damage; if necessary, repair with HELICOIL THREAD INSERTS .

Tighten down first screws (1) and then screws (2).

Fig 12: Identifying Screws

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IMPORTANT: Steering gear and output shaft are not to come into contact!

When lowering, make sure there is enough distance (A) between steering gear and output shaft.

Move front axle towards front of vehicle with special tool 00 2 030 when lowering.

Fig 13: Identifying Distance Between Steering Gear And Output Shaft

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IMPORTANT: Risk of damage!
Follow operations must be carried out during lowering:

Remove all hydraulic lines on front axle support or anti-roll bar retaining bracket and tie up.
Version with active steering: Disconnect plug connection and expose connecting line up to hydraulic steering gear.