Anti-Roll Bar Front, Replacing

Anti-roll bar front, replacing

Special tools:
999 5006 LIFTING BAR 999 5006 Lifting Bar
999 5033 SUPPORT 999 5033 Support
999 5460 Lifting hook 999 5460 Lifting Hook

Note! On cars of an earlier design the anti-roll bar's bushings and cap are replaceable. On later designs the anti-roll bar's bushings and cap are vulcanized in the anti-roll bar and with that are not replaceable.

Note! Later designs replace earlier designs of the anti-roll bar.

Install the support rails 999 5033, bracket 999 5006 and lifting yoke 999 5460. Lift up the engine slightly






Note! The following section only applies to right-hand drive cars.

Remove the collision protection system over the steering gear (2 screws)






Remove:




- the protective casing under the engine (only early designs)
- the five nuts holding the steering gear in the sub-frame.

Note! Only right-hand drive cars. Remove the nut A on the collision protection.

Remove the screws on the oil pipe brackets from the front and rear of the sub-frame.

Position a mobile jack at the rear end of the sub-frame.





Remove:
- on both sides, the four screws holding the sub-frame brackets on the body.
- the two screws together with the brackets and washers.

Loose the front screws on the subframe about 10-15 mm. Lower the rear edge of the frame. Make sure the steering gear's screws are released from the sub-frame.

Note! Right-hand drive cars:Make sure that the collision protection between the steering gear and the sub-frame is not "pushed down" onto the oil pipe.

Remove:




- anti-roll bar from the control arms
- cap on the anti-roll bar
- the anti-roll bar.





Note! Right-hand drive cars: Lift the anti-roll bar. Remove the collision protection between steering gear and the sub-frame. Remove the anti-roll bar.





Note! When replacing the anti-roll bar on cars up to the following chassis numbers: 4-door 2099893, 5-door 2011547, carry out the next section.

Remove the clip for the canister hose. Loosen the canister hose by the joint. Cut a piece of protective hose about 480 mm , P/N 185507-1. Thread this over the canister hose and reconnect the joint.

Installation

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.

Install:




- the anti-roll bar
- the cap. Tighten to 50 Nm .
- the control arms for the anti-roll bar. Tighten to 50 Nm

Note! Right-hand drive cars: At the same time fit the collision protection between the steering gear and sub-frame.

Push up the rear edge of the sub-frame. Use a mobile jack




At the same time fit the steering gear's securing screws in the frame, and on right-hand drive cars , the collision protection screws too.

Install the sub-frame brackets.
Install new screws, oil the screws (M14) for the sub-frame loosely .Move the mobile jack to the front edge of the frame. Replace and oil the front screws for the frame. Do not tighten yet.
First tighten the screws on the left side of the frame. Tighten to 105 Nm . Angle tighten to 120° . Then tighten the right-hand side to the same value as the left-hand side.
Tighten all the bracket screws to 50 Nm .

Tighten:




- steering gear with 50 Nm . Use new nuts.
- the nut (A) for the collision protection (right-hand drive cars) with 50 Nm
- the oil pipe brackets on the front and rear edges of the sub-frame.

Note! The following section only applies to left-hand drive cars.

Install the protective casing under the engine (only early designs)

Install:

Note! This section only applies to right-hand drive cars.




- the collision protection system over the steering gear (2 screws). Tighten with 80 Nm
- the protective casing under the engine (early designs)

Remove the lifting tools.