Remove/install front brake control cable - AR42.20-P-0520CW
MODEL 204, 207
| >>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 and eyes caused by handling hot or glowing objects. | Wear safety gloves, protective clothing and safety glasses, if necessary. | AS00.00-Z-0002-01A | |
| Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. | AS00.00-Z-0017-01A | |
| Notes on bolted connections with self tapping screws | AH00.00-P-0007-01SF | ||
| 1 | Remove lower instrument panel cover on driver side | ||
| 2 | Remove cover from pedal assembly (1) | ||
| 3 | Remove floor covering in driver footwell | ||
| 4 | Secure vehicle to prevent it rolling away and release parking brake | ||
| 5 | Press down front separation point (2) using assembly tool and unhook front brake cable (3) | Fig 4 | |
| 6 | Unhook front brake cable (3) from pedal assembly (1) | Fig 3 | |
| 7 | Remove retaining clips (4) in the driver footwell | ||
| 8 | Pry rubber grommet (5) out of the propeller shaft tunnel | ||
| 9.1 | Remove both lower engine compartment paneling | Model 204.9 | AR61.20-P-1105CY |
| 9.2 | Remove engine compartment paneling | Model 204, 207 with gasoline engine except model 204.9 | AR61.20-P-1105EW |
| 9.3 | Remove bottom sections of sound proofing | Model 204, 207 with diesel engine except model 204.9 | AR94.30-P-5300EW |
| 10 | Release underfloor paneling in area of rear reinforcement brace | model 204 | |
| Model 207 | AR61.30-P-1001EC |
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| 11 | Remove rear reinforcement brace on frame floor assembly | *BA61.10-P-1003-01H | |
| 12 | Remove heat shields (6, 7) in area of propeller shaft center support bearing | ||
| 13 | Unhook front brake cable (3) on center separation point (8) | ||
| 14 | Unhook front brake cable (3) from bracket on underbody | Fig 3 | |
| Only perform steps 15 to 24 on vehicles with automatic transmission | |||
| 15 | Unscrew front bracket of exhaust system | See Remove/install exhaust system components Vehicles with gasoline engine | AR49.10-P-7100CW |
| 16 | Remove bolts (27) and bracket (25) of diesel particulate filter | Model 204 with engine 642 |
*BA27.40-P-1001-01E *BA49.10-P-1027-01AC |
| 17 | Remove exhaust gas recirculation lines from catalytic converters | Engine 272.982/984, 276 Engine 272.982/984: Remove/install exhaust line Engine 276: Remove/install exhaust gas recirculation positioner Model 204 except 204 with engine 276 Model 204 with engine 276 |
AR14.20-P-1020-01CDE AR14.20-P-1020FH *BA27.40-P-1001-01E *BA49.10-P-1031-01AC *BA49.10-P-1032-01AC *BA14.20-P-1003-01M *BA14.20-P-1004-01M |
| *BA49.10-P-1040-01AE | |||
| *BA49.10-P-1041-01AE | |||
| 18.1 | Detach clamp for diesel particulate filter on connecting pipe | Engine 642 | AR49.10-P-7100CWI |
| 18.2 | Detach catalytic converter from exhaust manifold | Engine 272, 273, 278 | AR49.10-P-7100CW |
| 19 | Unclip the oxygen sensor's electrical feed lines from retaining clamps | Engine 272, 273, 278 | |
| 20 | Remove shift rod on range selector lever of automatic transmission | Transmission 722.6 in model 204.3 Transmission 722.9 in model 204.3 (except 204.34) Transmission 722.9 in model 204.98 Transmission 722.6 in model 204.0/2, 207 Transmission 722.9 in model 240.0/2/90/95 (except 204.04/08/09/24/28/29), 207 Transmission 722.9 in model 240.04/24/34 Transmission 722.9 in model 204.08/09/28/29/98 |
AR27.10-P-0500CW AR27.10-P-0500CV AR27.10-P-0500CWA AR27.10-P-0500CWX |
| 21 | Support automatic transmission and secure to prevent it from falling down | ||
| 22.1 | Remove engine crossmember with rear engine mount | Except model 204.9 Model 204 without engine 156, model 207 Model 204 with engine 156 |
AR22.10-P-1180CW AR22.10-P-1180CMG |
| 22.2 | Detach engine crossmember from frame floor assembly | Model 204.9 | AR22.10-P-1180CW |
| 23 | Detach propeller shaft from transmission | Model 204 with engine 156, model 204.9, model 207 with engine 273, 278, 642 | AR41.10-P-0050CW |
| 24 | Lower the automatic transmission | ||
| 25 | Remove retaining clips (9) on propeller shaft tunnel | ||
| 26 | Pull out front brake cable (3) to the rear | ||
| 27 | Install in the reverse order | ||
| 28 | Adjust parking brake | Model 204 | AR42.20-P-0540CW |
| Model 207 | AR42.20-P-0540EW |
HOUSING
| Number | Designation | Transmission 722.9 in model 204 | Transmission 722.9 in model 207 | |
|---|---|---|---|---|
| BA27.40-P-1001-01E | Bolt, automatic transmission to crankcase | Nm | 39 | 39 |
EXHAUST SYSTEM
| Number | Designation | Engine 156, 271, 272 in model 204 | |
|---|---|---|---|
| BA49.10-P-1031-01AC | Bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner | Nm | 9 |
| BA49.10-P-1032-01AC | Bolt, exhaust gas recirculation line clamp to catalytic converter | Nm | 9 |
EXHAUST GAS RECIRCULATION
| Number | Designation | Engine 276 | |
|---|---|---|---|
| BA14.20-P-1003-01M | Bolt, exhaust gas recirculation line to exhaust system | Nm | 9 |
| BA14.20-P-1004-01M | Bolt, EGR line to exhaust gas recirculation valve | Nm | 9 |
EXHAUST SYSTEM
| Number | Designation | Engine 271, 272, 273, 276, 278 in model 207 | |
|---|---|---|---|
| BA49.10-P-1040-01AE | Bolt, flange for exhaust gas recirculation lines to exhaust gas recirculation positioner | Nm | 9 |
| BA49.10-P-1041-01AE | Bolt, exhaust gas recirculation line clamp to catalytic converter | Nm | 9 |
EXHAUST SYSTEM
| Number | Designation | Engine 642, 646, 651 in model 204 | |
|---|---|---|---|
| BA49.10-P-1027-01AC | Bolt/nut, bracket of diesel particulate filter to lower diesel particulate filter | Nm | 20 |
FRAME FLOOR ASSEMBLY
| Number | Designation | Model 204 | Model 207.3 | Model 207.4 | |
|---|---|---|---|---|---|
| BA61.10-P-1003-01H | Bolt, rear reinforcement brace to frame floor assembly | Nm | 24 | 24 | 24 |