–
–
–
–
–
–
–
–
–
–
–
–
–
–
–

6
Nuts
Supporting mount - 65A.49.376 (LH) / 65A.49.377 (RH)
Rubber stop
Bellows
Mounting ring on bellows
Upper spring plate
Upper ring on bellows
Auxiliary spring
Intermediate ring
Coil spring
Lower spring plate (install with a distance of 10 mm from the lift system)
Spring strut
Plastic cap
Lift system (carried over from standard chassis)
Lock nut

Mounting bellows:
Check the type of bellows. Different types are available: with and without retaining
ring.

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Installing bellows mounting ring: Secure lift unit to prevent turning by fully screwing
down lower spring plate  6 -9- and securing with grub screw. Tightening
torque 1 Nm (0.7 ftlb.)
Tighten mounting ring for bellows  6 -4.1- (use hook spanner 685 11 296),
countering at lower spring plate  6 -9- (use hook spanner 685 11 295).
Tightening torque 15 Nm (11.1 ftlb.)
Install bellows mounting ring  6 -4.1- at short end of the bellows  6 -4-, install
upper spring plate  6 -4.2- on bellows  6 -4- and secure with upper bellows
ring  6 -5-.
The bellows  6 -4- is clipped onto the plastic cap when the spring strut is
completely installed.
4.6

Assembling new front spring strut without front axle lift
Information
The new front spring strut without front axle lift comes pre-mounted. The assembly
instructions are provided for the sake of completeness.
4.6.1

Install spacers  7 -14- on the piston rod.
Install components  7 -9-2- on piston rod and tighten nut  7 -1- (use special
tool KW 685 10 179).
Medium-strength Loctite must be used. Tightening torque 40 Nm (29.5
ftlb.)

1
2
3
4

–
–
–
–

7
Nuts
Supporting mount - 65A.49.376 (LH) / 65A.49.377 (RH)
Rubber stop
Bellows

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5
6
7
8
9
13
14

4.7

–
–
–
–
–
–
–

Upper spring plate
Auxiliary spring
Intermediate ring
Coil spring
Spring plate, lower
Spring strut
Spacers

Adjust the relevant dimension X.
On vehicles with a lift system, ensure that the
lift system line is aligned with the center of the
damping force adjustment wheel (A).
1
2
3

– Front axle with front axle lift
– Front axle without front axle lift
– Rear axle

8

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Front axle with front axle lift

Dimension A

Lower edge of spring seat to shoulder of lift unit

10 mm

Front axle with front axle lift

Dimension X

Lower edge of lift unit lock nut to shoulder of
shock absorber-valve foot

103 mm

Front axle without front axle lift

Dimension X

Lower edge of spring seat to shoulder of
damper-valve foot

110 mm

Rear axle

Dimension X

Lower edge of spring seat to shoulder of
damper-valve foot

96 mm

4.8

Tighten spring plate grub screws.
Tightening torque 1 Nm (0.7 ftlb.)

4.9

Only for spring strut with lift system: Tighten lift system lock nut (use open-ended spanner
700 17 171 and open-ended spanner 700 17 184).
Tightening torque 66 Nm (48.7 ftlb.)

Tequipment

Installation and Conversion Instructions
4.10

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Install front spring strut.  Workshop Manual '408519 Removing and installing front spring
strut'
Ensure the lift system line is not twisted or under strain.
When installing the spring strut, slide the strut bearing plate in the body connection
as far as possible towards the outside of the vehicle.

4.11

Replacing rear spring strut
4.11.1

Remove rear spring strut.  Workshop Manual '427119 Removing and installing
spring strut, rear'

4.11.2

Check height dimension X and adjust if necessary.

4.11.3

4.12

Rear axle

Dimension X

Lower edge of spring seat to shoulder of
damper-valve foot

96 mm

Install rear spring strut.  Workshop Manual '427119 Removing and installing
spring strut, rear'
Do not complete the vehicle interior.

Installing front-axle deactivation set
Use a suitable pin removal tool to replace the
electric wiring harness.
1
2
3
4
5
6

–
–
–
–
–
–

Front axle resistors
Adhesive pads
Plug
Rear axle resistors
Adhesive pads
Cable tie

9

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4.12.1

Replacing both original wiring
harness connectors:
Release safety cap  10 -2- on
locking lugs  10 -5-.
Release connector  10 -4- lock
 10 -3-.
1
2
3
4
5

–
–
–
–
–

Electric lines
Locking cap
Plug
Fuse
Locking lugs

10
4.12.2

Release connector  11 -2- lock
 11 -1- and unpin electric lines 
11 -3-.
1
2
3

4.12.3

– Plug
– Fuse
– Electric lines

Remove safety cap  10 -2- (no
longer required).

11
4.12.4

Plug electric lines  12 -1- into
new connector  12 -2- and lock
fuse  12 -3-.
1
2
3

– Electric lines
– Plug
– Fuse

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Installation and Conversion Instructions
4.12.5

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Installing front-axle deactivation set
on the right vehicle side:
Bring new connector  13 -1- into
contact with vehicle connector 
13 -2-.
Affix resistor  13 -4- on a level
surface using the supplied adhesive
pads.
Route the electric wire harness 
13 -3- without tension and secure
with a cable tie.
1
2
3
4

4.12.6

911 (992)

–
–
–
–

New connector
Vehicle connector
Electric wiring harness
Resistance

13

Installing front-axle deactivation set
on the left vehicle side:
Connect new plug connection  14
-1- with plug connection  14 -2for vehicle.
Affix resistor  14 -4- on a level
surface using the supplied adhesive
pads.
Route the electric wire harness 
14 -3- without tension and secure
with a cable tie.
1
2
3
4

–
–
–
–

New connector
Vehicle connector
Electric wiring harness
Resistance

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4.13

Installing rear-axle styling set
4.13.1

4.14

Bring new connectors  15 -3- into
contact with vehicle connectors 
15 -4-.
Isolate wiring harness  15 -2from power supply and secure with
cable tie.
Affix resistors  15 -1- on a level
surface in the middle of the vehicle
using the supplied adhesive pads.

Complete vehicle interior.  Workshop
Manual '427119 Removing and installing rear
spring strut - “Subsequent work” section'

15

WARNING
Danger of injury and damage from brake fluid
•

Poisonous if swallowed

•

Irritation and damage to skin

•

Avoid contact with paint surfaces



Only store brake fluid in suitable, labelled containers



Wear protective gloves and goggles



In the event of contact (eyes or skin), wash immediately with water



In the event of contact with paint surfaces, wash off immediately with water - do not wipe off
5

Installing brake lines
1

5.1

– Brake line sections (steel braided), front axle
and rear axle - 992. 044. 856.15
Conversion of front axle area
Longer section is installed on the front axle.
5.1.1

Loosen threaded connections 
17 -2- and remove brake line  17
-1-.

5.1.2

Install new brake line  17 -1without tension and ensuring no
abrasion occurs.

5.1.3

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Tighten all threaded connections  17 -2-.

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Installation and Conversion Instructions

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Tightening torque 10 Nm (7.4
ftlb.)
1