Removing the Sealing Ring and Piston With O-Ring For the Front Servo

Removing the sealing ring and piston with O-ring for the front servo

Special tools:
999 5717 Lifting eye 999 5717 Lifting Eye

Note! Location: Opposite the steering gear on the gearbox.

Note! To access it the sub-frame must be lowered and the steering gear removed.

Removal

Preparations




Slacken off the 5 hose clamps for all the charge air pipes.
Remove the 2 screws from the charge air pipe on the intake manifold. Heat carefully with a hot air gun.
Separate all the air pipes. Leave the pipes lying on the spark plug cover.

Removing the spark plugs cover





Remove:
- the screws for the spark plug cover
- the cover.

Applies only to turbocharged engines:
Remove the screws.
Lift up the delivery lines. Remove the spark plug cover.

Installing lifting fixture




Remove the 2 screws at the engine mounting.
Install the fixture 999 5717 Lifting eye 999 5717 Lifting Eye.

Installing the lifting beam and lifting hook on the engine lifting eyelet
Install the lifting beam and the lifting hook.

Disconnecting the front suspension components
Remove the front suspension components.

Removing the screws for the cable conduit and ground lead bracket on the sub-frame





Remove:
- the screw for the front engine pad (see the arrow)
- the screw for the torque rod in the gearbox.

Note! Cars with parking heaters: Remove the nuts for the heater from the sub-frame. Hang the heater on the left front fender.

Removing the nut for the ball joint pinion (left hand side)





Remove:
- the nut for the ball joint pinion on the left-hand side of the control arm

Note! Counterhold the ball joint pinion so that the boot is not locked.

- the nut for the link to the anti-roll bar on the left-hand side.

Removing the screws from the sub-frame support plates (both sides)
Remove the screws from the sub-frame support plates. Gearbox, Removing.

Pressing up the sub-frame on the right-hand side
Press up the rear edge of the sub-frame. Gearbox, Removing.

Removing the nuts and screws for the steering gear sub-frame




Remove the nuts and the screws from the steering gear sub-frame.

Removing the front cross member
Remove the front cross member.

Removing the bracket for the heated oxygen sensor (HO2S) wiring




Remove the screws for the bracket in the sub-frame holding the heated oxygen sensor (HO2S) cable. Push the bracket to one side.
Disconnect the connectors from the sub-frame.
Disconnect the heated oxygen sensor (HO2S) wiring from the sub-frame.

Removing the screw for the rear engine mounting




Remove the screw.

Preparatory work for removing the stub axle on the left-hand side
Prepare for removal.

Lowering the sub-frame




Use the mobile jack. Lower the sub-frame approximately 5 cm.
Hang the steering gear from a tie strap.
Carefully lower the sub-frame. Let it hang free.

Note! Ensure that the screws for the steering gear release from the frame.

Preparations for removing the servo cylinder




Press the steering gear backwards as far as possible.
Disconnect the wiring from the stud.
Wipe and blow the servo cylinder cover clean.
Take out a container for the oil.

Removing the cover




Place the container under the gearbox.
Remove the three studs.
Pull out the cover slightly, so that the oil runs out.
Fold down the and remove the cover.
Remove the piston from the gearbox. Pull it straight out.

Replacing the piston with O-ring and sealing ring





Hint: Press the piston against a bench so that the spring clip is easier to remove.

Replace the piston and the O-ring.
Replace the catch.
Replace the sealing ring for the cover.