How to change front suspension strut on Mercedes Vito W638 – replacement guide
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Important!
This replacement procedure can be used for:
MERCEDES-BENZ VITO Bus (638) 108 D 2.3 (638.164),
MERCEDES-BENZ VITO Bus (638) 110 TD 2.3 (638.174),
MERCEDES-BENZ VITO Bus (638) 113 2.0 (638.114, 638.194),
MERCEDES-BENZ VITO Bus (638) 114 2.3 (638.134, 638.194),
MERCEDES-BENZ VITO Bus (638) 108 CDI 2.2 (638.194),
MERCEDES-BENZ VITO Bus (638) 110 CDI 2.2 (638.194)
…
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The steps may slightly vary depending on the car design.
How to change a front shock strut on MERCEDES-BENZ VITO 1 (W638) [TUTORIAL AUTODOC]
All the parts you need to replace – Shock Absorber for VITO Bus (638) and other MERCEDES-BENZ models
Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
Step 3
Undo the fastening screws of the air filter cover. Use a Phillips screwdriver.
Step 4
Release the air filter cover clips.
Step 5
Unscrew the fasteners of the vacuum pressure converter valve.
Use a Phillips screwdriver.
Step 6
Unplug the mass air flow sensor connector.
Step 7
Detach the air intake hose clamp. Use a drive socket #7. Use a ratchet wrench.
Step 8
Disconnect the air intake pipe from the air filter housing. Use a crowbar.
Step 9
Take off the filter lid.
Step 10
Cover the air intake hose with a microfibre towel to prevent dust and dirt from getting into the system.
Step 11
Clean the fasteners of the shock strut upper mount. Use WD-40 spray.
Step 12
Loosen the upper fastener of the shock strut mount. Use a combination spanner #21. Use HEX No.H6.
Step 13
Secure the wheels with chocks.
Step 14
Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 15
Raise the front of the car and secure on supports.
Step 16
Unscrew the wheel bolts.
AUTODOC recommends:
Important! Hold the wheel while unscrewing the fastening bolts. Mercedes Vito W638
Step 17
Remove the wheel.
Step 18
Clean the fasteners of the ABS sensor and of the brake hose which connect them to the shock strut. Use a wire brush. Use WD-40 spray.
Step 19
Disconnect the wiring and the brake hose from the bracket on the shock strut. Use a crowbar.
Step 20.1
Clean the fasteners connecting the stabiliser link to the shock strut, and those connecting the shock strut to the steering knuckle.
Step 20.2
Use a wire brush. Use WD-40 spray.
Step 21
Unscrew the nut and remove the stabilizer rod from the shock strut. Use a combination spanner #16. Use a drive socket #16.
Step 22
Make a mark on the camber adjustment bolt.
Step 23
Unscrew the lower fastener connecting the shock strut to the steering knuckle. Use a combination spanner #21. Use a drive socket #21. Use a tap wrench.
Step 24
Prop up the steering knuckle. Use a hydraulic transmission jack.
Step 25
Remove the fastening bolts.
Step 26
Disconnect the steering knuckle from the shock absorber strut.
Step 27
Unscrew the top fastening of the shock strut mount.
To avoid injuries, hold the shock strut when undoing the fastening bolts.
Step 28
Remove the suspension strut.
Step 29
Set the shock absorber strut on the spring compressor tool.
Replacement: suspension strut – Mercedes Vito W638. 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 30
Compress the spring.
Step 31
Clean the shock absorber rod. Use WD-40 spray.
Step 32
Remove the strut piston rod nut. Use a combination spanner #21. Use HEX No.H6.
Step 33
Remove the top strut mount.
Step 34
Release the coil spring.
Step 35
Remove the spring.
Step 36
Remove the shock absorber dust cap and the bump stop.
Step 37
Remove the old shock absorber from the hydraulic coil spring compressor.
AUTODOC recommends:
Replacement: suspension strut – Mercedes Vito W638. Carefully inspect the mount, the boot, and the bump stop of the shock absorber. Replace if necessary.Before installing a new shock absorber you should pump it manually 3-5 times.
Step 38
Install the new shock absorber on the hydraulic coil spring compressor.
Step 39
Install the dust sleeve and the bump stop on the new shock absorber.
Step 40
Install the spring on the shock absorber.
Step 41
Compress the spring.
Step 42
Install the upper strut mount and the strut mount bearing. Use a crowbar.
Step 43
Tighten the shock strut piston rod nut. Use a combination spanner #21. Use HEX No.H6. Use a torque wrench. Tighten it to 66 Nm torque.
Lower the hydraulic transmission jack smoothly, without jerks, to avoid damaging assemblies and mechanisms.
Step 53
Tighten the lower fasteners connecting the shock strut to the steering knuckle. Use a drive socket #21. Use a combination spanner #21. Use a torque wrench. Tighten it to 190 Nm torque.
Step 54
Secure the stabilizer link on the suspension strut. Use a combination spanner #16. Use a drive socket #16. Use a torque wrench. Tighten it to 62 Nm torque.
Step 55
Connect the fastener of the ABS sensor cable to the shock absorber strut. Fasten the brake hose on the strut.
Step 56
Treat the shock strut fasteners. Treat all joints of the arm. Use copper grease.
Step 57
Clean the wheel rim mounting seat. Use a wire brush. Treat the contacting surface. Use copper grease.
Step 58
Install the wheel.
AUTODOC recommends:
To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 59
Screw in the wheel bolts. Use wheel impact socket #17.
Step 60
Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 175 Nm torque.
Step 61
Tighten the upper fastener of the shock absorber strut mount. Use a combination spanner #21. Use HEX No.H6. Use a torque wrench. Tighten it to 66 Nm torque.
Step 62
Remove the cloth.
Step 63
Reinstall the air filter cover. Fasten it.
Step 64
Connect the air intake pipe to the air filter housing.
Step 65
Press the air filter cover clips into place.
Step 66
Screw in the fastening screws of the air filter cover. Use a Phillips screwdriver.
Step 67
Plug in the mass air flow sensor conntector.
Step 68
Screw in the fasteners of the vacuum pressure converter valve.
Step 69
Fasten the clamp on the air intake hose. Use a drive socket #7. Use a ratchet wrench.
Step 70
Remove the fender protection cover.
Step 71
Close the hood.
Step 72
Remove the jacks and chocks.
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