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Remove/install rack-and-pinion steering - AR46.20-P-0600EW

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MODEL 204.9, 212 without CODE 211 (Direct-Steer system) 

Shown on vehicle with engine 272 

Fig 1: Rack-And-Pinion Steering Remove/Install Components
G09976707Courtesy of MERCEDES-BENZ USA
DANGER Risk of injury  to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning  from swallowing hydraulic fluid. Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses. AS00.00-Z-0013-01A
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
IMPORTANT Evaluating steering gear when repairing accident vehicles   AH46.20-P-9409-01A
REMOVINGINSTALLING Remove/install     
1 Deactivate easy entry/exit function MODEL 204.9, 212
with CODE 275 (Memory package)
without CODE 211 (Direct-Steer system)		  
2 Turn steering wheel into center position (front wheels in straight-ahead position) and fix in position with retaining device NOTES The steering wheel must not be turned when detaching steering coupling.
Otherwise the clock spring contact will be destroyed.		  
SPECIAL TOOL Retainer device Figure
3 Open engine hood MODEL 204.9, 212
without CODE 211 (Direct-Steer system)		  
MODEL 212 AR88.40-P-1000EW
4.1 Remove the left engine intake air duct ENGINE 272, 273  
4.2 Remove upper engine cover Engine 642, 651
INSTALLATION IMPORTANT Ignition switched off.		  
4.3 Remove front engine cover MODEL 212 with ENGINE 156
without CODE 211 (Direct-Steer system)
NOTES Do not tilt front engine cover, but lift it off vertically toward top.
Otherwise the retaining lug could break off.		  
5 Extract oil from power steering expansion reservoir NOTES Before opening the hydraulic system, thoroughly clean the area surrounding the separation point.
Even the smallest dirt particles, introduced into the hydraulic components, can lead to malfunctions and a total failure of the hydraulic system.		  
SPECIAL TOOL Hand pump Fig 3
6 Remove the front wheels    
REFER TO MAINTENANCE MODEL 204.9 AP40.10-P-4050CW
REFER TO MAINTENANCE MODEL 212 AP40.10-P-4050EW
7.1 Remove center and rear section of lower engine compartment paneling Model 212 with gasoline engine  
AR61.20-P-1105EW
7.2 Remove center and rear bottom sections of soundproofing MODEL 212 with diesel engine  
AR94.30-P-5300EW
7.3 Detach lower engine compartment paneling MODEL 204.9  
AR61.20-P-1105CY
8 Remove tie rods from steering knuckles   AR46.40-P-0200-02CW 
TORQUE SPECIFICATION
MODEL 204.9, 212
without CODE 211 (Direct-Steer system)		 *BA46.40-P-1001-01N 
SPECIAL TOOL Thrust piece Figure
SPECIAL TOOL Puller Figure
SPECIAL TOOL Puller Figure
SPECIAL TOOL Press Figure
9 Detach steering coupling from rack-and-pinion steering (10) MODEL 204.9 AR46.10-P-8000CW
MODEL 212
INSTALLATION IMPORTANT Replace self-locking nut.		 AR46.10-P-8000EW 
TORQUE SPECIFICATION
MODEL 204.9, 212
without CODE 211 (Direct-Steer system)		 *BA46.10-P-1001-01M 
10 Disconnect electrical connector from speed-sensitive power steering (Y10) MODEL 204.9, 212
with CODE 213 (Speed-sensitive power steering)
without CODE 211 (Direct-Steer system)
IMPORTANT If necessary, detach cable tie from electrical line.		  
11 Remove bolt (12) from rack-and-pinion steering (10) TORQUE SPECIFICATION
MODEL 204.9, 212
without CODE 211 (Direct-Steer system)		 *BA46.20-P-1003-01N 
12 Remove bolt (15) and remove bracket (16) from rack-and-pinion steering (10) TORQUE SPECIFICATION
MODEL 204.9
without CODE 211 (Direct-Steer system)		 *BA46.20-P-1004-01N 
13 Pry clamping plate (9) off rack-and-pinion steering (10) and pull out power steering oil lines (13, 14) IMPORTANT Place oil lines for power steering (13, 14) to one side and seal all openings using SPECIAL TOOL stop plugs.
INSTALLATION IMPORTANT Replace O-rings.		  
SPECIAL TOOL Record plug Fig 7
14 Support rack-and-pinion steering (10) and secure to prevent it from falling down    
15 Remove bolt (10c) from additional bracket or additional mounting of rack-and-pinion steering (10) to front axle carrier (11) TORQUE SPECIFICATION
MODEL 204.9
without CODE 211 (Direct-Steer system)		 *BA46.20-P-1010-01N 
16 Remove bolts (10a, 10b) INSTALLATION IMPORTANT Replace bolts (10a, 10b).  
TORQUE SPECIFICATION Fastening, rack-and-pinion steering to front axle carrier *BA46.20-P-1001-01N 
TORQUE SPECIFICATION Bolt, retaining plate for rack-and-pinion steering to front axle carrier *BA46.20-P-1002-01N 
17 Take out retaining plate (8) with rack-and-pinion steering (10)    
18 Install in the reverse order    
19 Fill power steering pump and bleed MODEL 204.9 AR46.30-P-0010CW
MODEL 212 AR46.30-P-0010EW 
20 Check front axle toe and adjust if necessary MODEL 204.9 AR40.20-P-0200CW
MODEL 212
IMPORTANT After installation of new parts.		 AR40.20-P-0200EW
STEERING SHAFT

Number Designation MODEL 204 MODEL 212
BA46.10-P-1001-01M Nut/bolt, steering coupling to steering shaft Nm 30 30
STEERING GEAR

Number Designation MODEL 204 except 4MATIC, except 204.9 MODEL 204 with 4MATIC, with MODEL 204.9
BA46.20-P-1001-01N Fastening, rack-and-pinion steering to front axle carrier Stage 1 Nm 70 100
Stage 2 ∠° 90 90
STEERING GEAR

Number Designation MODEL 212 except 4MATIC MODEL 212 with 4MATIC
BA46.20-P-1001-01N Fastening, rack-and-pinion steering to front axle carrier Stage 1 Nm 70 100
Stage 2 ∠° 90 90
STEERING GEAR

Number Designation MODEL 204 except 4MATIC, except 204.9 MODEL 204 with 4MATIC, with MODEL 204.9
BA46.20-P-1002-01N Bolt, retaining plate for rack-and-pinion steering to front axle carrier M12 Nm 110 110
STEERING GEAR

Number Designation MODEL 212 except 4MATIC MODEL 212 with 4MATIC
BA46.20-P-1002-01N Bolt, retaining plate for rack-and-pinion steering to front axle carrier M12 Nm 110 110
STEERING GEAR

Number Designation MODEL 204 except 4MATIC, except 204.9 MODEL 204 with 4MATIC, with MODEL 204.9
BA46.20-P-1003-01N Bolt, clamp plate, high-pressure line/return line to rack-and-pinion steering control head Nm 21 21
STEERING GEAR

Number Designation MODEL 212 except 4MATIC MODEL 212 with 4MATIC
BA46.20-P-1003-01N Bolt, clamp plate, high-pressure line/return line to rack-and-pinion steering control head Nm 21 21
STEERING GEAR

Number Designation MODEL 204 except 4MATIC, except 204.9 MODEL 204 with 4MATIC, with MODEL 204.9
BA46.20-P-1004-01N High pressure and low-pressure hoses to rack-and-pinion steering housing M6 Nm 10 10
STEERING GEAR

Number Designation MODEL 204 except 4MATIC, except 204.9 MODEL 204 with 4MATIC, with MODEL 204.9
BA46.20-P-1010-01N Bolt, steering gear rack-and-pinion steering to front axle carrier M8 Nm 28 28
TIE ROD

Number Designation MODEL 204 MODEL 212
BA46.40-P-1001-01N Self-locking nut, tie rod to steering knuckle Stage 1 Nm 50 50
Stage 2 ∠° 60 90
Fig 2: Identifying Retainer Device (129 589 01 21 00)
G09976708Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Hand Pump (210 589 00 71 00)
G09976709Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Puller (221 589 05 33 00)
G09976710Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Puller (221 589 00 33 00)
G09976711Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Thrust Piece (171 589 00 34 00)
G09976712Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Record Plug (129 589 00 91 00)
G09976713Courtesy of MERCEDES-BENZ USA
Fig 8: Identifying Press (163 589 03 43 00)
G09976714Courtesy of MERCEDES-BENZ USA
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