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How to change front suspension strut on MERCEDES-BENZ VIANO (W639) – replacement guide

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Important!

This replacement procedure can be used for:
MERCEDES-BENZ VIANO (W639) CDI 2.2 (639.811, 639.813, 639.815, 639.711, 639.713), MERCEDES-BENZ VIANO (W639) CDI 2.2 (639.811, 639.813, 639.815, 639.711, 639.713), MERCEDES-BENZ VIANO (W639) CDI 3.0 (639.811, 639.813, 639.815), MERCEDES-BENZ VIANO (W639) 3.2 (639.711, 639.811, 639.813), MERCEDES-BENZ VIANO (W639) 3.2 (639.713, 639.813, 639.815), MERCEDES-BENZ VIANO (W639) CDI 2.2 (639.711, 639.713, 639.811, 639.813, 639.815), MERCEDES-BENZ VIANO (W639) CDI 2.0 (639.711, 639.713, 639.811, 639.813, 639.815), MERCEDES-BENZ VIANO (W639) 3.7 (639.815), MERCEDES-BENZ VIANO (W639) CDI 3.0 (639.811, 639.813, 639.815), MERCEDES-BENZ VIANO (W639) CDI 2.0 (639.711, 639.713, 639.811, 639.813, 639.815), MERCEDES-BENZ VIANO (W639) 3.5 (639.811, 639.813, 639.815), MERCEDES-BENZ VIANO (W639) 3.7 (639.811, 639.813, 639.815) … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

Alternative products

Shock absorber

Replacement: suspension strut – MERCEDES-BENZ VIANO (W639). List of the tools you'll need:

                      Wire brush
                    
                      WD-40 spray
                    
                      Brake cleaner 
                    
                      Copper grease 
                    
                      Torque wrench
                    
                      Torx bit T25
                    
                      Torx bit T40
                    
                      Combination spanner #18
                    
                      Combination spanner #21
                    
                      Drive socket # 13 
                    
                      Drive socket # 20 
                    
                      Drive socket # 21 
                    
                      Wheel impact socket #17
                    
                      Ratchet wrench
                    
                      Flat Screwdriver
                    
                      Hydraulic strut spring compressor
                    
                      Ear clamp pliers
                    
                      Fender cover
                    
                      Wheel chock

Buy tools

Replacement: suspension strut – MERCEDES-BENZ VIANO (W639). AUTODOC recommends:

Both shock struts of the front suspension should be replaced simultaneously.
The replacement procedure is identical for the left and right shock struts of the front suspension.
All work should be done with the engine stopped.

Replacement: suspension strut – MERCEDES-BENZ VIANO (W639). Recommended sequence of steps:

Step 1

Secure the wheels with chocks.
Step 2

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 3

Raise the front of the car and secure on supports.

Step 4

Unscrew the wheel bolts.

AUTODOC recommends:
Important! Hold the wheel while unscrewing the fastening bolts. MERCEDES-BENZ VIANO (W639)
Step 5

Remove the wheel.
Step 6

Clean the stabiliser link fasteners. Use a wire brush. Use WD-40 spray.

Step 7

Unscrew the fastener connecting the stabilizer link to the shock strut. Use a combination spanner #18. Use Torx T40. Use a ratchet wrench.
Step 8

Remove the stabilizer rod.
Step 9

Detach the brake hose from the shock strut. Use a flat screwdriver.
Step 10

Disconnect the ABS sensor wiring. Disconnect the fastener of the brake pad wear sensor wire from the suspension strut. Use a flat screwdriver.
Step 11

Clean the fasteners connecting the shock strut to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 12

Unscrew the fasteners connecting the suspension strut to the steering knuckle. Use a combination spanner #21. Use a drive socket #21. Use a ratchet wrench.
Step 13

Remove the fastening bolts.
Step 14

Disconnect the steering knuckle from the shock absorber strut.
Step 15

Lower the car.

Step 16

Open the bonnet.

Step 17

Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.

Step 18

Unscrew the fasteners of the cowl grille. Use Torx T25. Use a ratchet wrench.
Step 19

Remove the clips of the plastic cowl grille. Use a flat screwdriver. Use ear clamp pliers.
Step 20

Unscrew the fasteners of the windscreen wiper arms. Use a drive socket #13. Use a ratchet wrench.
Step 21

Remove the wiper arms.
Step 22

Detach the windscreen washer nozzle hose.
Step 23

Raise up and remove the cowl grille. Use a flat screwdriver.
Step 24

Take out the cabin filter bracket. Use Torx T25. Use a ratchet wrench.
Step 25

Remove the lower wiper plastic cowl grille.
Step 26

Detach the windscreen washer nozzle hose.
Step 27

Unscrew the fasteners of the windscreen wiper linkage panel. Use a drive socket #13. Use a ratchet wrench.
Step 28

Remove the panel assembled with the windscreen wiper linkage.
Step 29

Unplug the wiper motor connector. Use a flat screwdriver.
Step 30

Remove the suspension strut mount cap. Use a flat screwdriver.
Step 31

Clean the upper fastener of the suspension strut mount. Use a wire brush. Use WD-40 spray.

Step 32

Unscrew the top fastening of the shock strut mount. Use a drive socket #21. Use a ratchet wrench.

Replacement: suspension strut – MERCEDES-BENZ VIANO (W639). Tip:
To avoid injuries, hold the shock strut when undoing the fastening bolts.
Step 33

Remove the suspension strut.
Step 34

Set the shock absorber strut on the spring compressor tool.

Replacement: suspension strut – MERCEDES-BENZ VIANO (W639). Tip from AUTODOC experts:
Note that when using a spring compressor, spring coils need to be securely gripped, compressing the spring on the opposite sides.Ensure the correct position of the spring in the retainer.Make sure that the spring coils tightly entered the lock handles.
Step 35

Compress the spring.
Step 36

Treat the shock strut rod. Use WD-40 spray.
Step 37

Remove the strut piston rod nut. Use a drive socket #20. Use a ratchet wrench.
Step 38

Remove the shock absorber mount, dust boot, and bump stop.

AUTODOC recommends:
Replacement: suspension strut – MERCEDES-BENZ VIANO (W639). Carefully inspect the mount, the boot, and the bump stop of the shock absorber. Replace if necessary.
Step 39

Release the coil spring.

Step 40

Remove the spring.
Step 41

Remove the old shock absorber from the hydraulic coil spring compressor.

Replacement: suspension strut – MERCEDES-BENZ VIANO (W639). Tip from AUTODOC:
Before installing a new shock absorber you should pump it manually 3-5 times.
Step 42

Install the new shock absorber on the hydraulic coil spring compressor.
Step 43

Install the spring on the shock absorber.
Step 44

Install the mount, dust boot, and bump stop on a new shock absorber.
Step 45

Compress the spring.

Step 46

Tighten the shock strut piston rod nut. Use a drive socket #20. Use a torque wrench. Tighten it to 56 Nm torque.

Replacement: suspension strut – MERCEDES-BENZ VIANO (W639). AUTODOC experts recommend:
Check to make sure the spring is positioned correctly. Avoid its misalignment.
Step 47

Decompress the spring.

Step 48

Remove the assembled shock strut.
Step 49

Install the shock strut into the wheel arch.
Step 50

Screw the top fastening of the shock strut mount.

AUTODOC recommends:
Important! Hold the suspension strut while screwing in the fastening bolts. MERCEDES-BENZ VIANO (W639)
Step 51

Tighten the upper fastener of the shock absorber strut mount. Use a drive socket #21. Use a torque wrench. Tighten it to 56 Nm torque.
Step 52

Install the shock strut mount cap.
Step 53

Plug in the wiper motor connector.
Step 54

Install the panel assembled with the windscreen wiper linkage.

Step 55

Screw in the fasteners of the windscreen wiper linkage panel. Use a drive socket #13. Use a torque wrench. Tighten it to 27 Nm torque.
Step 56

Attach the windscreen washer nozzle hose.
Step 57

Install and secure the cowl grille.
Step 58

Install the cabin filter bracket. Use Torx T25. Use a torque wrench. Tighten it to 11 Nm torque.
Step 59

Tighten the fasteners of the cowl grille. Use Torx T25. Use a ratchet wrench.
Step 60

Install and secure the cowl grille.
Step 61

Install the fasteners of the wiper plastic cowl grille.
Step 62

Reinstall the wiper arms.
Step 63

Tighten the fasteners of the wiper arms. Use a drive socket #13. Use a torque wrench. Tighten it to 24 Nm torque.

Replacement: suspension strut – MERCEDES-BENZ VIANO (W639). Tip from AUTODOC experts:
Make sure not to mix up the wiper arms on the driver's and passenger's sides.
Step 64

Attach the windscreen washer nozzle hose.
Step 65

Remove the fender protection cover.

Step 66

Close the hood.

Step 67

Raise the front of the car and secure on supports.

Step 68

Treat the shock strut mounting seat on the steering knuckle. Use a wire brush. Use WD-40 spray.

Step 69

Fix the shock absorber strut on the steering knuckle.
Step 70

Install the fastening bolts.
Step 71

Tighten the lower fasteners connecting the shock strut to the steering knuckle. Use a combination spanner #21. Use a drive socket #21. Use a torque wrench. Tighten it to 120 Nm torque.+75°

AUTODOC recommends:
Important! Be sure to use new fasteners.
Step 72

Secure the stabilizer link on the suspension strut.
Step 73

Tighten the fastener connecting the stabilizer link to the shock strut. Use a combination spanner #18. Use Torx T40. Use a torque wrench. Tighten it to 85 Nm torque.
Step 74

Fasten the brake hose on the strut. Use a flat screwdriver.
Step 75

Connect the fastener of the ABS sensor cable to the shock absorber strut. Connect the fastener of the brake pad wear sensor wire to the suspension strut.
Step 76

Treat the shock strut fasteners. Treat all joints of the stabiliser link. Use copper grease.
Step 77

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 78

Clean the brake disk surface. Use a brake cleaner.

Replacement: suspension strut – MERCEDES-BENZ VIANO (W639). Tip:
After applying the spray, wait a few minutes.
Step 79

Install the wheel.

Replacement: suspension strut – MERCEDES-BENZ VIANO (W639). Tip from AUTODOC:
To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 80

Screw in the wheel bolts. Use wheel impact socket #17.
Step 81

Lower the car and working in a cross order, tighten the wheel bolts. Use wheel impact socket #17. Use a torque wrench. Tighten it to 130 Nm torque.
Step 82

Remove the jacks and chocks.

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