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Remove/install power steering pump - AR46.30-P-0500CMG

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MODEL 204 with ENGINE 156 

Fig 1: Power Steering Pump Remove/Install Components
G10241449Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER Risk of injury  caused by fingers being pinched or crushed  when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof Keep body parts and limbs well clear of moving parts. AS00.00-Z-0011-01A
DANGER 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
DANGER 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 hydraulic system completely before starting any work on system. Wear protective clothing and safety glasses. AS00.00-Z-0013-01A
    NOTES Before opening the hydraulic system the area surrounding the separation point should be cleaned thoroughly. Even the smallest dirt particles, introduced into the hydraulic components, can lead to malfunctions and a total failure of the hydraulic system.  
1 Remove engine intake air duct and front engine cover NOTES Do not tilt front engine cover, but lift upwards vertically. Otherwise the retaining lugs can break off  
2 Extract oil from power steering expansion reservoir SPECIAL TOOL Figure
3 Remove poly-V belt   AR13.20-P-0001CMG
4 Loosen engine mounts from below   AR22.10-P-1260CMG
5 Attach engine lifting device, lift engine and slide to the right   AR33.10-P-0105CW
6 Detach refrigerant compressor (A9) IMPORTANT Put the refrigerant compressor (A9) with lines connected to one side. AR83.55-P-5300CMG
7 Detach hydraulic line (8) from power steering pump (1); to do this, remove banjo bolt (7) INSTALLATION IMPORTANT Replace sealing rings. Attach banjo bolt (7) from above.
IMPORTANT Seal openings using stop plugs.
 
TORQUE SPECIFICATION *BA46.30-P-1004-01R 
SPECIAL TOOL Figure
8 Remove bolts (4) and take out support (5) INSTALLATION IMPORTANT Attach ground cable (9).  
TORQUE SPECIFICATION *BA46.30-P-1007-01R 
TORQUE SPECIFICATION *BA46.30-P-1008-01R 
9 Detach electrical line (11) from power steering pump (1); for this purpose, separate cable ties (10)    
10 Remove screw (6) TORQUE SPECIFICATION *BA46.30-P-1001-01R 
11 Remove bolts (2) TORQUE SPECIFICATION *BA46.30-P-1002-01R 
12 Detach feed line (3) from power steering pump (1)    
13 Remove power steering pump (1) upwards    
14 Install in the reverse order    
INSPECT Checking     
DANGER Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.
AS00.00-Z-0005-01A
15 Run engine and check power steering for leaks    
POWER STEERING PUMP

Number Designation Model 204 without engine 651
BA46.30-P-1001-01R Power steering pump to crankcase   Nm 20
BA46.30-P-1002-01R Power steering pump/tandem pump to timing case Self-tapping threads Nm 35
Normal threads Nm 20
BA46.30-P-1004-01R Attachment, high pressure expansion hose of rack-and-pinion steering to power steering pump or tandem pump Union nut Nm 40
Banjo bolt Nm 45
Bolt M8 Nm 18
BA46.30-P-1007-01R Bolt, support holder to cylinder crankcase   Nm 20
BA46.30-P-1008-01R Bolt, support holder to power steering pump   Nm 20
Fig 2: Identifying Hand Pump (210 589 00 71 00)
G10241450Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Set Of Stop Plugs (129 589 00 91 00)
G10241451Courtesy of MERCEDES-BENZ USA