2003-2009 Mercedes-Benz E500 4MATIC Wagon Front Conversion Kit Installation Manual - Strutmasters
2003-2009 Mercedes-Benz E500 4MATIC Wagon Front Conversion Kit Installation Manual
Take a look at our easy-to-follow 2003-2009 Mercedes-Benz E500 4MATIC Wagon Front Conversion Kit Installation Manual to learn how to install your new Strutmasters air suspension conversion kit. Our step-by-step instructions include pictures to help you along the way.
Mercedes-Benz E500 4MATIC Wagon parts included in this kit:
- MI24F: 2 Coilover Strut Assemblies, 2 Eibach coil springs, 2 mounts, 2 pucks, and 2 gas/hydraulic shocks.
- MI24FM: 2 Coilover Strut Assemblies, 2 Eibach coil springs, 2 mounts, 2 pucks, 2 gas/hydraulic shocks, and a suspension light disarm module.
- Disconnect Battery
- Read general service precautions
- Wear Eye Protection
- Support the vehicle
- Remove air suspension parts
- Install conversion kit
Tools needed for installation:
- Metric sockets
- Metric wrenches
- Floor jack or vehicle lift
- Jack stands
- Screw drivers (Phillips and Flat-Head)
- Allen wrenches and metric torque bits
- Cut-off Wheel
- General Tools
Front Air Strut Removal InstructionsStep 1
Caution: A sudden release of pressure may cause personal injury or damage to the vehicle. The air suspension system is under pressure until the air supply lines are disconnected. Use the following precautions when servicing the air suspension system: Wear gloves, ear protection, and eye protection. Wrap a clean cloth around the air supply lines. The vehicle must be raised to perform this conversion! Use proper lifting equipment only! Read instructions carefully before attempting installation, if you have problems during the install then feel free to call our Technical Support Line. Please before calling for technical help, have your invoice handy.
- Locate battery in trunk. Disconnect (-) negative cable from battery.
- Locate under hood fuse box on driver side, near bottom of wind shield, see Fig 1.
- Remove compressor relay K67 at rear corner by pulling straight up. See Fig 2.
- CAUTION: Front struts and must be emptied using STARS DIAGNOSIS. If this is not available loosen each air fitting slowly to allow air pressure to escape.
- Unplug wire harness from top of strut (Fig 3).
- Remove the three nuts from the studs along with the black support plate, see Fig 4. Save the plate.
- Raise vehicle with wheels straight ahead. Remove front wheels.
- Remove front fender forward section of wheel liner. See Fig 5.
- Disconnect struts electrical connector. See Fig 6.
- Remove sway bar bolt on both sides of the vehicle to allow sway bar to drop down. This gives you access to the lower strut bolt. See Fig 7.
- Remove brake line from the struts horseshoe shaped lower mounting bracket. See Fig 8.
- Remove the CV axle bolt in the center of the brake rotor, see Fig 9.
- Place a jack stand under the lower control arm to support it. Now remove the upper ball joint nut, see Fig 10.
- Hold onto the spindle arm and Separate the upper control arm from the spindle arm.
- Lower the jack stand and slowly lay back the spindle arm. MAKE SURE the CV shaft comes out of the spindle arms hub. You may have to push the shaft out of the hub as you lay back the spindle arm. See Fig 11 & Fig 12. CAUTION: Do not pull on either end of the CV shafts. You may dislodge the ball bearings inside the boots by doing so.
- We highly recommend that you cut one side of the lower horseshoe-shaped bracket off with a cut-off wheel at the bottom of the strut to reduce the risk of any damage to the CV shaft and to aid in removal of the strut. The front CV shafts are very expensive to replace. The best area to cut is just above the brake line bracket. The reason we recommend cutting is due to the difficulty of removing the passenger side CV shaft without damage.
- Ensure the brake line is removed and out of the way.
- Cut the arm at the white line above the brake line bracket. This allows you to remove the strut without damaging or removing the CV shaft. See Fig 13.
- After cutting the bracket, remove the lower strut mounting bolt from the lower control arm, see Fig 14. CAUTION: The strut will fall when you remove this bolt! So be sure to have a hold of it!
- Now you will be able to remove the strut from the vehicle.
- Do the same procedures to the other front strut to remove it.
Front Conversion Kit Installation InstructionsStep 2
- Remove the nuts from the top of the new strut.
- Place top of the strut up into the three stud holes in the fender. Note: The thread holes in the lower strut bracket should face the front of the vehicle as in Fig 1.
- Place a nut on the front stud, see Fig 2. DO NOT TIGHTEN NUT YET.
- Now with the CV shaft out of the hub as in Fig 3, work the lower strut bracket over the CV boot. Note: This bracket is a tight fit, so be patient and do not rip the rubber boot. A silicone spray may help.
- Install the lower strut bracket to control arm. Install bolt with the threads of the bolt facing the rear of the vehicle. Do not tighten bolt! See Fig 4.
- Place the CV shaft back into the hub and reconnect the spindle arm to upper ball joint. Tighten nut. Note: You may need to jack up the lower control arm, see Fig 5.
- Install the CV shaft bolt into the hub and tighten to factory spec, see Fig 6.
- Tighten the strut to lower control arm bolt To factory spec, see Fig 7.
- Attach the supplied brake-line bracket to the inboard hole on the lower strut bracket. Tighten. Press brake line into bracket, Fig 8.
- Install the black support plate over the rear two studs at the top of the strut, see Fig 9.
- Install the remaining nuts on the studs and tighten.
- Install opposite side strut before reconnecting sway bar.
- Reconnect sway bar. Fig 10.
Front Conversion Kit installation complete.