Remove/install front brake control cable - AR42.20-P-0520CW
MODEL 204, 207
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of injury . Skin or eye injuries may result when handling hot or glowing objects. | Wear protective 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 | ||
| Remove/install | |||
| 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) | Do not unhook the front brake cable (3) using pliers. The rubber guard can otherwise be damaged. |
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| Figure | |||
| 6 | Unhook front brake cable (3) from pedal assembly (1) | Figure | |
| 7 | Remove retaining clips (4) in the driver footwell | ||
| 8 | Pry rubber grommet (5) out of the propeller shaft tunnel | ||
| 9 | Remove lower engine compartment paneling or bottom sections of soundproofing | MODEL 204.0/2 with ENGINE 156, 271, 272, 274, 276 MODEL 204.3 with ENGINE 156, 271, 274, 276 MODEL 207 with ENGINE 271, 272, 273, 274, 276, 278 |
AR61.20-P-1105EW |
| MODEL 204.9 | AR61.20-P-1105CY | ||
| MODEL 204.0 with ENGINE 642, 646, 651 MODEL 204.2 with ENGINE 642, 646, 651 MODEL 204.3 with ENGINE 651 MODEL 207 with ENGINE 642, 651 |
AR94.30-P-5300EW | ||
| 10 | Release underfloor paneling in area of rear reinforcement brace | MODEL 204, 207 | |
| MODEL 207 | AR61.30-P-1001EC | ||
| 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 | Figure | |
| 15 | Unscrew front bracket of exhaust system | MODEL 204, 207 with TRANSMISSION 722 | |
| TRANSMISSION 722 in MODEL 204 with ENGINE 156 TRANSMISSION 722 in MODEL 204 with ENGINE 271 TRANSMISSION 722 in MODEL 204 with ENGINE 272 TRANSMISSION 722 in MODEL 204 with ENGINE 274 TRANSMISSION 722 in MODEL 204 with ENGINE 276 TRANSMISSION 722 in MODEL 207 with ENGINE 271 TRANSMISSION 722 in MODEL 207 with ENGINE 272 TRANSMISSION 722 in MODEL 207 with ENGINE 273 TRANSMISSION 722 in MODEL 207 with ENGINE 276 TRANSMISSION 722 in MODEL 207 with ENGINE 278 |
AR49.10-P-7100CW | ||
| TRANSMISSION 722 in MODEL 204 with ENGINE 642 TRANSMISSION 722 in MODEL 204 with ENGINE 651 TRANSMISSION 722 in MODEL 207 with ENGINE 642 TRANSMISSION 722 in MODEL 207 with ENGINE 651 |
AR49.10-P-7100CWI | ||
| 16 | Remove bolts (27) and bracket (25) of diesel particulate filter | MODEL 204 with ENGINE 642 with TRANSMISSION 722 | |
| *BA49.10-P-1027-01AC | |||
| 17 | Remove exhaust gas recirculation lines from catalytic converters | MODEL 204 with ENGINE 272.982 with TRANSMISSION 722 MODEL 207 with ENGINE 272.982/984 with TRANSMISSION 722 |
AR49.10-P-7100CW |
| MODEL 204, 207 with ENGINE 276.9 with TRANSMISSION 722 | AR14.20-P-1020FH | ||
| 18.1 | Detach clamp for diesel particulate filter on connecting pipe | MODEL 204, 207 with ENGINE 642, 651 | |
| AR49.10-P-7100CWI | |||
| 18.2 | Detach catalytic converter from exhaust manifold | MODEL 204 with ENGINE 272 with TRANSMISSION 722 MODEL 207 with ENGINE 272 with TRANSMISSION 722 MODEL 207 with ENGINE 273 with TRANSMISSION 722 MODEL 207 with ENGINE 276.9 with TRANSMISSION 722 |
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| AR49.10-P-7100CW | |||
| 19 | Unclip the oxygen sensor's electrical feed lines from retaining clamps | MODEL 204 with ENGINE 272 with TRANSMISSION 722 MODEL 207 with ENGINE 272 with TRANSMISSION 722 MODEL 207 with ENGINE 273 with TRANSMISSION 722 MODEL 207 with ENGINE 278 with TRANSMISSION 722 |
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| 20 | Remove shift rod on range selector lever of automatic transmission | MODEL 204, 207 with TRANSMISSION 722.6/9 | |
| MODEL 204.0/2/3 with TRANSMISSION 722.6 up to model year 2012/AEJ11MODEL 207 with TRANSMISSION 722.6 |
AR27.10-P-0500CW | ||
| MODEL 204 with TRANSMISSION 722.9 (except 722.96/997) MODEL 207 with TRANSMISSION 722.9 (except 722.96) |
AR27.10-P-0500CV | ||
| MODEL 204.04/24/34 with TRANSMISSION 722.997 | AR27.10-P-0500CWA | ||
| MODEL 204.0/2/9 with TRANSMISSION 722.96 MODEL 207.3 with TRANSMISSION 722.96 |
AR27.10-P-0500CWX | ||
| 21 | Support automatic transmission and secure to prevent it from falling down | MODEL 204, 207 with TRANSMISSION 722 | |
| 22.1 | Remove engine crossmember with rear engine mount | MODEL 204 (except 204.9), 207 with TRANSMISSION 722 | |
| MODEL 204 (except 204.9) with ENGINE 272 with TRANSMISSION 722 MODEL 204 (except 204.9) with ENGINE 274 with TRANSMISSION 722 MODEL 204 (except 204.9) with ENGINE 276 with TRANSMISSION 722 MODEL 204 (except 204.9) with ENGINE 642 with TRANSMISSION 722 MODEL 204 (except 204.9) with ENGINE 646 with TRANSMISSION 722 MODEL 204 (except 204.9) with ENGINE 651 with TRANSMISSION 722 MODEL 204 with ENGINE 271 with TRANSMISSION 722 MODEL 207 with ENGINE 271 with TRANSMISSION 722 MODEL 207 with ENGINE 272 with TRANSMISSION 722 MODEL 207 with ENGINE 273 with TRANSMISSION 722 MODEL 207 with ENGINE 274 with TRANSMISSION 722 MODEL 207 with ENGINE 276 with TRANSMISSION 722 MODEL 207 with ENGINE 278 with TRANSMISSION 722 MODEL 207 with ENGINE 642 with TRANSMISSION 722 MODEL 207 with ENGINE 651 with TRANSMISSION 722 |
AR22.10-P-1180CW | ||
| MODEL 204 with ENGINE 156 with TRANSMISSION 722 | AR22.10-P-1180CMG | ||
| 22.2 | Detach engine crossmember from frame floor assembly | MODEL 204.9 with ENGINE 272 with TRANSMISSION 722 MODEL 204.9 with ENGINE 274 with TRANSMISSION 722 MODEL 204.9 with ENGINE 276 with TRANSMISSION 722 MODEL 204.9 with ENGINE 642 with TRANSMISSION 722 MODEL 204.9 with ENGINE 651 with TRANSMISSION 722 |
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| AR22.10-P-1180CW | |||
| 23 | Detach propeller shaft from transmission | MODEL 204, 207 with TRANSMISSION 722 | AR41.10-P-0050CW |
| 24 | Lower the automatic transmission | MODEL 204, 207 with TRANSMISSION 722 |
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| 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 | AR42.20-P-0540CW | |
| AR42.20-P-0540EW |
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 | |
|---|---|---|---|---|
| BA61.10-P-1003-01H | Bolt, rear reinforcement brace to frame floor assembly | Nm | 24 | 24 |
FRAME FLOOR ASSEMBLY
| Number | Designation | MODEL 207.4 | |
|---|---|---|---|
| BA61.10-P-1003-01H | Bolt, rear reinforcement brace to frame floor assembly | Nm | 24 |