Remove/install front axle - AR33.10-P-0100N

MODEL 215 

MODEL 220 with CODE (487) Active Body Control (ABC) 

MODEL 230 

Fig 1: Identifying Front Axle Remove/Install Components - Shown On Model 220

Shown on model 220 

	Remove/install
	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
	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
	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 into a different position if the driver door is opened or closed for example. 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 retainer.	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.
			Figure
4.1	Extract oil from expansion reservoir of power steering pump	Vehicles without active body control (ABC)
		Hand pump	Figure
4.2	Extract oil from expansion reservoir of tandem pump	Vehicles with Active Body Control (Code 487) only.
		Hand pump	Figure
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
			Figure
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)	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)
	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 hoses (39) and seal connections.	Seal off line terminals immediately with stop plugs. The brake fluid expansion reservoir must not be allowed to run completely empty. Installation:  The brake hose must not be twisted after tightening (risk of cracking). When releasing or fastening the brake line on the brake hose make sure that its bracket is not twisted. When undoing and tightening the brake line, use an open end wrench to counterhold the brake hose's double edge.
		Set of stop plugs	Figure
		Box wrench bit	Figure
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on installing brake hoses		AH42.10-P-9406-01A
			*BA42.10-P-1001-04A
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 capsule	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.
			*BA62.30-P-1004-01A
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-1018-01A
		Thrust piece	Figure
		Puller	Figure
15	Undo 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	Insert a suitable tool into the hole in the steering coupling (25) or hole in the lower steering shaft (80a) and pull the lower steering shaft (80a) out and up from 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	Unscrew bolts (40c) of both suspension struts (40)	Model 215, 220 Installation:  Bolts (40c) after tightening must lie flush with the suspension strut (40) or be slightly recessed.
		Bolt, front suspension strut to spring control arm	*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
		Nut, front suspension strut to spring control arm	*BA32.25-P-1007-04B
		Puller	Fig 7
		Thrust piece	Figure
19	Mount the engine support frame and raise the 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
		Engine support frame http://gotis.aftersales.daimlerchrysler.com
		Model 220.028/ 128 Load regulator (engine hoist), self-locking http://gotis.aftersales.daimlerchrysler.com  Additional hanger for load regulator (engine hoist) http://gotis.aftersales.daimlerchrysler.com	AR01.10-P-7500-03M
20	Unscrew bolts (1g) and remove engine mount from front axle carrier (1)	Model 215, 220 except 220.028/ 128	*BA22.10-P-1001-01L
		Model 220.028/ 128	*BA22.10-P-1001-01D
		Model 230	*BA22.10-P-1001-01X
21	Prop front axle carrier (1) using transmission platform and transmission jack		AR33.10-P-0100-03I
		Telescopic transmission jack http://gotis.aftersales.daimlerchrysler.com  Passenger car transmission platform http://gotis.aftersales.daimlerchrysler.com
22	Unscrew 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 Only on model 220. Installation:  Before tightening the bolts (1f), align the front axle carrier (1) on the left and right using drift (a, 14.8 mm diameter). After this, insert rubber plugs.
		Drift set	Figure
			*BA33.10-P-1003-01A
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 line connections with plugs.
		Set of stop plugs	Figure
		High-pressure stretch hose to rack-and-pinion steering	*BA46.20-P-1002-01E
		Return line to rack-and-pinion steering	*BA46.20-P-1001-01E
		Bolt on clamp plate, high-pressure line / return line to rack-and-pinion steering	*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 Active Body Control (ABC) code 487	AR32.25-P-1017R
		Model 230 without Active Body Control (ABC) code 487	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	Fill power steering pump and bleed	Vehicles with Active Body Control (Code 487) only.	AR46.30-P-0010N
		Vehicles without Active Body Control (Code 487) only.	AR46.30-P-0010B
31.1	Bleed brake system with STAR DIAGNOSIS	Model 230 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. When performing the bleeding operation, it is essential to observe the instructions in the document "Bleeding brake system using STAR DIAGNOSIS":
		Bleed brake system using STAR DIAGNOSIS.	AR42.10-P-0012R
	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

ENGINE MOUNTS, ENGINE SUPPORTS

ENGINE MOUNTS, ENGINE SUPPORTS

ENGINE MOUNTS, ENGINE SUPPORTS

ENGINE MOUNTS, ENGINE SUPPORTS

ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS

STRUTS

FRONT AXLE CARRIER

WHEEL LOCATION, HUB

BRAKE LINES, BRAKE HOSES

STEERING SHAFT

STEERING GEAR

CROSSMEMBER AND FRONT REINFORCEMENT

Fig 2: Identifying Holding Device (129 589 01 21 00)

Fig 3: Identifying Guard Plate (220 589 01 31 00)

Fig 4: Identifying Box Wrench Bit (000 589 75 03 00)

Fig 5: Identifying Thrust Washer M 10x1.5 (210 589 04 63 00)

Fig 6: Identifying Puller (202 589 02 33 00)

Fig 7: Identifying Puller (230 589 00 33 00)

Fig 8: Identifying Hand Pump (210 589 00 71 00)

Fig 9: Identifying Thrust Piece (140 589 00 63 00)

Fig 10: Identifying Set Of Stop Plugs (129 589 00 91 00)

Fig 11: Identifying Drift Set (220 589 00 15 00)