Remove/install protective cap for input shaft on steering gear - AR46.20-P-0004P

MODEL 169, 171, 203, 204, 209, 211, 230, 245 

Shown on model 203, left-hand drive vehicle 

(Left illustration) Model 169 up to 30.3.05, left-hand drive vehicle 

(Middle illustration) Model 169, 245, right-hand drive vehicle 

(Right illustration) Model 169 as of 31.3.05, model 245, left-hand drive vehicle 

Shown on model 203, left-hand drive vehicle 

Shown on model 203, right-hand drive vehicle 

Shown on model 211, left-hand drive vehicle 

Shown on model 211, right-hand drive vehicle 

Shown on model 230, left-hand drive vehicle 

Shown on model 230, right-hand drive vehicle 

	Removing
1	Mount rack-and-pinion steering onto steering gear housing mounting device	Ensure that the workplace is clean when carrying out the work described below and while performing repairs! Only the specified tool may be used! Before starting repair, remove loose dirt from steering gear without using cleaning agent!
			Figure
2	Detach inner clamps (1) of both bellows (2)
3	Slide bellows (2) towards tie rod end	To do so push outer clamps together.
4	Remove inner track rod with axial joint (3)	Do not use force (hammer blows, excessive leverage) otherwise the inner tie rod with axial joint (3) will be damaged. Dismantle at left and right sides.
			Figure
5	Move steering rack to center position	Use depth gauge to determine when the assembly is centered. Balance out the gaps from the end of the steering rack to the stop ring (16) in the steer jacket (14) on both sides of the steering rack.
6	Detach protective cap (4)
	Install
7	Grease gap between input shaft and control head (arrow)	Except model 169, 245 Apply grease using fingers. Do not use any other aid.
		Renolit JP1619 special grease	*BR00.45-Z-1067-06A
8	Fit protective cap (4)	Marking (5) must line up exactly with marking (6) as otherwise the Electronic Stability Program (ESP) may malfunction. Model 169, 245: There are various versions of the protective cap (4). The version fitted must always be reinstalled.
	Modified rack-and-pinion steering	Model 169 as of 31.3.05	BT46.20-P-0600-01AK
	Checking
9	Check center steering position on steering gear		AR46.20-P-3015P
10	Mount the inner tie rod with axial joint (3)	Do not use force (hammer blows, excessive leverage) otherwise the inner tie rod with axial joint (3) will be damaged. Mount on left and right sides.
			*BA46.40-P-1003-01E
			*BA46.40-P-1003-01J
			*BA46.40-P-1003-01N
			Figure
11	Mount bellows (2)
12	Mount inner clamps (1) of both bellows (2)	Replace clamps (1).
13	Detach rack-and-pinion steering from steering gear housing mounting device

Number	Designation		Model 169	Model 245
BA46.40-P-1003-01J	Inner tie rod to rack-and-pinion steering	Nm	80	80

Number	Designation		Model 171	Model 203 except model 203.081/084/ 087/092/281/ 284/287/292	Model 203.081/084/ 087/092/281/ 284/287/292
BA46.40-P-1003-01E	Inner track rod with axial joint to rack-and-pinion joint	Nm	110	110	110

Number	Designation		Model 209	Model 211 except 211.08/09/ 28/29	Model 211.08/09/ 28/29	Model 230
BA46.40-P-1003-01E	Inner track rod with axial joint to rack-and-pinion joint	Nm	110	110	110	110

Number	Designation		Model 204
BA46.40-P-1003-01N	Inner tie rod to rack-and-pinion steering	Nm	110

Number	Designation	Order number
BR00.45-Z-1067-06A	Renolit JP1619 special grease	A 001 989 38 51 10