Running gear, Axles, Steering, Front and four wheel drive

Kapitelübersicht

• Technical data
  1
• 1 Technical data
  1
• 1.1 Running gear
  1
• 1.2 Wheels, tyres
  1
• 2 Checklist for evaluating running gear of accident vehicles
  2
• 3 General information
  4
• Front suspension
  5
• 1 Appraisal of accident vehicles
  5
• 2 Electrical/electronic components and locations
  6
• 2.2 Vehicle level sender G78 on front axle
  7
• 2.3 Vehicle level sender G78 on front axle, R32
  8
• 2.4 Vehicle level sender G76 on rear axle, front-wheel drive
  9
• 2.5 Vehicle level sender G76 on rear axle, four-wheel drive
  10
• 3 Repairing front suspension
  12
• 3.1 Overview - front axle
  12
• 3.2 I - Assembly overview, subframe, anti-roll bar and suspension link
  13
• 3.3 Modified fastening for anti-roll bar
  15
• 3.4 Checking swivel joint
  15
• 3.5 Removing and installing swivel joint
  16
• 3.6 Removing and installing suspension link
  18
• 3.7 Renewing suspension link bushes
  20
• 3.8 Removing and installing subframe
  23
• 3.9 Renewing bonded rubber bushes in subframe
  25
• 3.10 Repairing threads in longitudinal member
  27
• 3.11 II - Assembly overview - wheel bearing
  27
• 3.13 III - Assembly overview - suspension strut
  38
• 3.14 Vehicle data sticker
  40
• 3.15 Removing and installing suspension strut
  40
• 3.16 Repairing front coil spring suspension strut
  42
• 4 Repairing front suspension, R32
  45
• 4.1 Overview - front axle
  45
• 4.2 I - Assembly overview - subframe, anti-roll bar and suspension link
  46
• 4.3 Checking swivel joint
  47
• 4.4 Removing and installing swivel joint
  48
• 4.5 Removing and installing suspension link
  50
• 4.6 Renewing suspension link bushes
  50
• 4.7 Removing and installing subframe
  53
• 4.8 Renewing bonded rubber bushes in subframe
  55
• 4.9 Repairing threads in longitudinal member
  57
• 4.10 II - Assembly overview - wheel bearing
  58
• 4.11 Pressing out and pressing in front wheel bearing
  63
• 4.12 III - Assembly overview - suspension strut
  67
• 4.13 Removing and installing suspension strut
  68
• 4.14 Repairing front coil spring suspension strut
  71
• 5 Repairing front drive shafts
  73
• 5.1 Overview - drive shafts
  73
• 5.2 Removing and installing drive shafts
  74
• 5.3 I - Repairing front drive shaft with constant velocity joint
  78
• 5.4 Checking outer constant velocity joint
  84
• 5.5 Checking inner constant velocity joint
  85
• 5.6 II - Repairing front drive shaft with constant velocity joint VL 3700
  87
• 5.7 III - Repairing front drive shaft with triple roller joint AAR 2000
  91
• 5.8 Dismantling and assembling triple roller joint
  94
• 5.9 IV - Repairing front drive shaft with triple roller joint AAR 2900
  96
• 5.10 Dismantling and assembling triple roller joint AAR 2900
  100
• 5.11 V - Repairing drive shaft with triple roller joint AAR 3300i
  104
• 5.12 Dismantling and assembling triple roller joint AAR 3300i
  108
• Rear suspension
  111
• 1 Appraisal of accident vehicles
  111
• 2 Repairing rear axle
  112
• 2.1 Removing and installing rear axle
  112
• 2.2 Assembly overview - rear axle beam
  116
• 2.3 Removing and installing bonded rubber bush
  119
• 2.4 Removing and installing hydraulic bonded rubber bush
  123
• 2.5 Removing and installing spring/shock absorber
  128
• 2.6 Assembly overview - shock absorber on vehicle with front-wheel drive
  130
• 3 Repairing wheel bearing
  132
• 3.1 Repairing wheel bearing, front-wheel drive vehicles
  132
• 3.2 Removing and installing wheel bearing/wheel hub on vehicles with disc brakes
  133
• 3.3 Removing and installing wheel bearing/hub unit on vehicles with drum brakes
  136
• 4 Repairing rear axle (vehicles with four-wheel drive)
  139
• 4.1 Rear axle for four-wheel drive: exploded view
  139
• 4.2 Removing and installing spring
  140
• 4.3 Removing and installing spring, R32
  145
• 4.4 Removing and installing shock absorber
  151
• 5 Assembly overview - trailing arm and transverse links
  155
• 5.1 Pressing rear wheel bearing out and in with trailing arm installed
  158
• 5.2 Removing and installing trailing arm bush
  162
• 5.3 Removing and installing upper ball joints/bonded rubber bushes
  165
• 5.4 Removing and installing lower ball joint/bonded rubber bush
  169
• 5.5 Removing and installing trailing arm
  173
• 5.6 Removing and installing transverse link
  177
• 6 Assembly overview for subframe with final drive
  181
• 6.1 Removing and installing subframe
  181
• 6.2 Removing and installing subframe bushes
  185
• 6.3 Removing and installing bonded rubber bushes for final drive
  187
• 7 Repairing rear drive shaft
  190
• 7.1 Removing and installing rear drive shafts
  190
• 7.2 Repairing drive shaft with rear constant velocity joint
  192
• Self-levelling suspension
  199
• Wheels, tyres, vehicle geometry
  200
• 1 Appraisal of accident vehicles
  200
• 2 Torque settings for wheel bolts
  201
• 3 Wheel alignment
  202
• 3.1 General
  202
• 3.2 Test prerequisites:
  203
• 3.3 Test preparations
  203
• 3.4 Vehicle data sticker
  204
• 3.5 Wheel alignment specifications
  205
• 3.6 Adjusting camber at front axle
  208
• 3.7 Adjusting camber on rear axle, vehicles with front-wheel drive
  209
• 3.8 Adjusting rear axle camber, vehicles with four-wheel drive
  209
• 3.9 Adjusting toe setting on rear axle (front-wheel drive vehicles)
  210
• 3.10 Adjusting toe setting at rear wheels (four-wheel drive vehicles)
  210
• 3.11 Adjusting front axle toe
  211
• 3.12 Checking left and right-hand wheel lock
  211
• 4 Wheels, tyres
  213
• 4.1 Removing and installing wheel trim cap
  213
• 5 Wheels, tyres
  214
• 5.1 Models with breakdown set
  214
• 5.2 Tyre sealant
  214
• 5.3 Removing a tyre
  214
• 5.4 Fitting a new tyre
  215
• 5.5 Tyre sealant disposal
  215
• 6 Instructions for changing or fitting wheels
  216
• 6.1 Fitting wheels
  217
• 7 Protecting wheel centring seat against corrosion
  218
• 8 Vibration due to wheels/tyres - causes and rectification
  219
• 8.1 Causes of vibration
  219
• 8.2 Balancing wheels
  219
• 8.3 Conducting a road test before balancing wheels
  219
• 8.4 Balancing wheels on stationary wheel balancing machine
  220
• 8.5 Vibration control system VAS 6230
  222
• 8.6 Finish balancer
  222
• 8.7 Radial and lateral run-out of wheels and tyres
  223
• 8.9 Checking radial and lateral run-out on wheel rim
  224
• 8.10 Matching
  225
• 8.11 Flat spots caused by storage or handling
  226
• Steering
  228
• 1 Appraisal of accident vehicles
  228
• 2 Airbag
  229
• 3 Steering column
  230
• 3.1 Removing and installing steering column
  230
• 3.2 Checking steering column for damage
  236
• 3.3 Removing and installing steering lock housing
  237
• 3.4 Assembly overview - crossmember for steering column
  238
• 3.5 Steering column variations
  239
• 3.6 Removing and installing locking cable for ignition with key removal lock
  240
• 3.7 Checking ignition key removal lock
  241
• 4 Repairing power steering
  242
• 4.1 Removing and installing power-assisted steering rack
  242
• 4.2 Assembly overview - power steering rack (LHD)
  247
• 4.3 Assembly overview - power steering rack (RHD)
  249
• 4.4 Assembly overview, power steering rack with heat shield (vehicles with four-wheel drive)
  250
• 4.5 Removing and installing track rod
  252
• 4.6 Revised track rod ball joints
  253
• 4.7 Revised track rods
  254
• 4.8 Checking play, tightness and bellows of track rod ball joints
  255
• 4.9 Determining centre position of steering rack
  255
• 4.10 Adjusting steering rack
  255
• 5 Vane pump, reservoir and hydraulic lines
  257
• 5.1 Checking delivery pressure of vane pump
  257
• 5.2 Removing and installing vane pump, vehicles with bottom-mounted vane pump
  262
• 5.3 Removing and installing vane pump, vehicles with top-mounted vane pump
  264
• 5.4 Assembly overview: vane pump with hydraulic lines
  268
• 5.5 Assembly overview - bottom-mounted power steering pump
  281
• 5.6 Assembly overview - top-mounted vane pump
  282
• 6 Definitions
  283