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Rear strut removal and installation - AR32.25-P-1016A

MODEL 140 as of 1.6.94, 210 with CODE (217a) Self-levelling suspension on rear axle with ADS with CODE (480) Level control system at rear 

MODEL 202, 203.2, 208 with CODE (480) Level control system at rear 

Fig 1: Identifying Rear Strut Remove/Install Components - Strut On Model Series 140, 202, 208 & 210.0
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Strut on Model Series 210.2, 210.6 

Fig 2: Identifying Rear Strut Remove/Install Components - Strut On Model Series 210.2, 210.6
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Strut on Model Series 203.2 

Fig 3: Identifying Rear Strut Remove/Install Components - Strut On Model Series 203.2
G04624732
REMOVINGINSTALLING Removing, installing     
NOTES The vehicle must be standing on its wheels for removing the top spring strut mounting.    
1 Remove trim panels from luggage compartment /cargo area    
2 Remove top spring strut mounting Model Series 140
Use Allen wrench (5 mm) to hold piston rod and prevent it from turning.		  
    SPECIAL TOOL Model Series 202, 208, 210.0 Figure
    IMPORTANTInstallation:  Replace self-locking nut (5a) on Model 140.
TORQUE SPECIFICATION Model Series 140 nut (5a) *BA32.30-P-1001-01A 		  
    TORQUE SPECIFICATION Model Series 202, 203, 208 nut (5p) *BA32.30-P-1001-01B 
    TORQUE SPECIFICATION Model Series 210.0 nut (5p) *BA32.30-P-1006-01A 
    TORQUE SPECIFICATION Model Series 202, 208 nut (5a) *BA32.30-P-1002-01B 
    TORQUE SPECIFICATION Model Series 210.0 nut (5a) *BA32.30-P-1005-01A 
    TORQUE SPECIFICATION 210.2, 210.6 Bolt (5g) *BA32.30-P-1007-01A 
3.1 Remove washer (5b) and rubber mount (5c) Model Series 202, 203, 208, 210.0  
3.2 Remove washer (5i) and rubber bushing (5c) Model Series 210.2, 210.6  
4 Cover all attached parts remaining in vehicle (area to be repaired)    
DANGER Risk of injury  to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning  from swallowing hydraulic fluid. Render the hydraulic system pressureless before commencing work on system. Wear protective clothing and eye protection. AS00.00-Z-0013-01A
5 Drain hydraulic system IMPORTANTInstallation:  Recharge hydraulic system AR32.30-P-0630A 
NOTES General notes for working on vehicles with level control / ADS All models with Code 216b, 216c, 217a, 480 AH32.00-P-0002-01A 
6.1 Disconnect high-pressure supply line (P4) at the joint where the steel pipe joins the hose Model Series 140, 210.2, 210.6
IMPORTANTInstallation:  Ensure that the high-pressure supply line (P4) is routed correctly.		  
    TORQUE SPECIFICATION Model Series 140 *BA32.30-P-1003-01A 
    TORQUE SPECIFICATION Model Series 210.2, 210.6 *BA32.30-P-1003-01A 
6.2 Disconnect high-pressure supply line (P4) from strut Model Series 202, 203, 208, 210.0  
    TORQUE SPECIFICATION Model Series 202, 208 *BA32.30-P-1004-01B 
    TORQUE SPECIFICATION Model Series 210.0 *BA32.30-P-1004-01B 
    IMPORTANTInstallation:  Replace radial seals at the banjo bolt (5v)  
    Before tightening pressure line at spring strut ↓ Check, adjust distance between strut and wheel-housing AR32.30-P-0610-01A 
7 Remove cover from track control arm (72c)    
8 Detach and remove spring strut (5) from spring link (72) IMPORTANTInstallation:  Pull apart spring strut so that the spring strut mount rests in the dome. Model Series 140: The metal plate on the strut bushing must be toward the front of the vehicle. Replace self-locking nut (5n).  
    TORQUE SPECIFICATION Model Series 140 *BA32.30-P-1003-01B 
    TORQUE SPECIFICATION Model Series 202, 203, 208 *BA32.30-P-1002-01A 
    TORQUE SPECIFICATION Model Series 210 *BA32.30-P-1002-01A 
INSPECT Inspecting     
9 Check rubber bushings (5c, 5d), strut bearing support (5e) and rubber boot for cracks and damage.
Check ball joint for wear		    
10 Check spring strut for leaks. IMPORTANT A fine oil mist is permitted.
If the joint socket is covered with oil ↓ replace the strut.		  
11 Reverse the removal sequence to install IMPORTANTafter installation:  Check distance between strut and wheel-housing with the vehicle ready to roll.  
    Model Series 202, 203, 208, 210.0: Loosen the upper strut mount and re-align the strut as necessary. AR32.30-P-0610-01A 
DANGER Injury hazard!  Drilling into gas-filled assemblies and components represents a potential injury hazard (the gas itself is not flammable) Wear safety glasses and face mask. AS00.00-Z-0006-01A
12 Dispose of shock-absorber strut    
REFER TO FORMS     OS32.25-P-0120-01A 
Rear strut test specifications

Number Designation Model Series 202 with ride-height control Model Series 203.2 with self-leveling suspension
BE32.30-P-1001-01A Distance between supply hose bracket on strut and wheel-housing with suspension extended left mm 11-15 11-15
right mm 24-28 24-28
Fig. see AR32.30-P-0610-01A  AR32.30-P-0610-01A 
BE32.30-P-1002-01A Distance between supply hose bracket on strut and wheel-housing ready to roll (standing on wheels) left mm 14-18 14-18
right mm 26-30 26-30
Fig. see AR32.30-P-0610-01A  AR32.30-P-0610-01A 
Rear strut test specifications

Number Designation Model 210.0 with level control system / AD Model Series 208 with self-leveling suspension
BE32.30-P-1001-01A Distance between supply hose bracket on strut and wheel-housing with suspension extended left mm 8.5-10.5 11-15
right mm 8.5-10.5 24-28
Fig. see AR32.30-P-0610-01A  AR32.30-P-0610-01A 
BE32.30-P-1002-01A Distance between supply hose bracket on strut and wheel-housing ready to roll (standing on wheels) left mm 10.5-12.5 14-18
right mm 10,5-12,5 26-30
Fig. see AR32.30-P-0610-01A  AR32.30-P-0610-01A 
TORQUE SPECIFICATION Rear strut

Number Designation Model Series 202 with ride-height control Model Series 203.2 with self-leveling suspension
BA32.30-P-1001-01B Nut of spring strut of level control to frame floor NM 18 18
BA32.30-P-1002-01B Locknut of spring strut of level control to frame floor NM 30 30
BA32.30-P-1003-01B Self-locking nut, ride-height control strut to track control arm NM 55 55
BA32.30-P-1004-01B Banjo bolt of pressure pipe of level control to spring strut NM 25 25
TORQUE SPECIFICATION Rear strut

Number Designation Model Series 208 with ride-height control
BA32.30-P-1001-01B Nut of spring strut of level control to frame floor NM 18
BA32.30-P-1002-01B Locknut of spring strut of level control to frame floor NM 30
BA32.30-P-1003-01B Self-locking nut, ride-height control strut to track control arm NM 55
BA32.30-P-1004-01B Banjo bolt of pressure pipe of level control to spring strut NM 25
TORQUE SPECIFICATION Rear strut

Number Designation Model Series 140 with ride-height control/ ADS Model 210.0 with level control system / ADS
BA32.30-P-1001-01A Self-locking nut, strut for self-leveling suspension/ADS to floorpan NM 40 -
BA32.30-P-1002-01A Self-locking nut, ride-height control/ADS strut to track control arm NM 100 55
BA32.30-P-1003-01A High-pressure supply line for self-leveling suspension at joint between strut steel pipe and supply hose (reference figure) M16 x 1.5 NM 30 30
BA32.30-P-1004-01A Banjo bolt, pressure pipe of level control to spring strut NM - 25
BA32.30-P-1005-01A Locknut of spring strut of level control to frame floor NM - 30
BA32.30-P-1006-01A Nut of spring strut of level control to frame floor NM - 17
TORQUE SPECIFICATION Rear strut

Number Designation Model Series 210.2 with self-leveling suspension/ ADS
BA32.30-P-1002-01A Self-locking nut, ride-height control/ADS strut to track control arm NM 55
BA32.30-P-1003-01A High-pressure supply line for self-leveling suspension at joint between steel pipe on strut and supply hose (reference figure) M16 x 1.5 NM 30
BA32.30-P-1007-01A Bolt, self-leveling suspension strut to frame NM 25
Fig 4: Identifying Socket Wrench (202 589 00 09 00)
G04624733
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