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

Kapitelübersicht

• Technical data
  1
• 1 Checklist for evaluating running gear of accident vehicles
  1
• 2 Technical data
  3
• 2.1 Running gear
  3
• 2.2 Steering
  4
• 2.3 Wheels, tyres
  4
• Front suspension
  5
• 1 Appraisal of accident vehicles
  5
• 2 Electrical/electronic components and locations
  6
• 2.2 Front left vehicle level sender G78 on front axle
  7
• 2.4 Rear left vehicle level sender G76 on rear axle of vehicles with four-wheel drive
  9
• 3 Repairing front suspension
  11
• 3.1 Raising wheel suspension to unladen position
  15
• 3.2 Modified wheel bearing housing/track rod ball joint
  17
• 3.3 Modified wheel bearing housing from model year 2002
  17
• 3.4 Modified track control link from model year 2002
  17
• 3.5 Modified coupling rod for anti-roll bar
  18
• 3.6 Repairing threads in longitudinal member
  19
• 3.7 Separating upper suspension link joint at wheel bearing housing
  19
• 3.8 Removing and installing suspension strut
  22
• 3.9 Repairing suspension strut
  24
• 3.10 Removing and installing spring
  26
• 3.11 Removing and installing wheel bearing housing
  30
• 3.12 Pressing out and pressing in front wheel bearing
  33
• 3.14 Checking the track control link
  42
• 3.15 Removing and installing track control link
  42
• 3.16 Renewing track control link bushes
  44
• 3.17 Removing and installing guide link
  46
• 3.18 Renewing guide link bushes
  48
• 3.19 Renewing anti-roll bar bushes
  50
• 3.20 Removing and installing mounting bracket
  50
• 3.21 Renewing bushes for front and rear upper links
  54
• 3.22 Removing and installing subframe
  55
• 3.23 Renewing subframe bushes
  61
• 4 Repairing drive shafts
  65
• 4.1 Removing and installing drive shafts
  65
• 4.2 Repairing drive shaft with constant velocity joint
  66
• 4.3 Repairing drive shaft with triple roller joint
  72
• 4.4 Dismantling and assembling triple roller joint
  75
• Rear suspension
  80
• 1 Appraisal of accident vehicles
  80
• 2 Repairing rear axle (front-wheel drive vehicles)
  81
• 2.1 Rear axle in unladen position
  81
• 2.2 Removing and installing rear axle
  82
• 2.3 Assembly overview - rear axle beam
  86
• 2.4 Removing and installing shock absorber/spring
  88
• 2.5 Assembly overview - shock absorber on vehicle with front-wheel drive
  89
• 3 Repairing wheel bearing
  91
• 3.1 Removing and installing wheel bearing/wheel hub unit
  91
• 3.2 Assembly overview - wheel mounting for vehicles with front-wheel drive
  91
• 4 Repairing rear axle (vehicles with four-wheel drive)
  93
• 4.3 Repairing suspension strut, vehicles with four-wheel drive
  97
• 4.4 Dismantling and assembling suspension strut
  98
• 4.5 Assembly overview of rear axle with four-wheel drive
  100
• 4.6 Removing and installing subframe
  103
• 4.7 Aligning subframe to vehicle
  106
• 4.8 Renewing bonded rubber bushes in subframe
  107
• 4.9 Assembly overview of subframe/final drive
  110
• 4.10 Pressing bonded rubber bush for cross member in and out
  111
• 4.11 Pressing bonded rubber bush for gearbox support in and out
  112
• 5.1 Removing and installing wheel bearing
  117
• 5.2 Pressing rear wheel bearing out and in with wheel bearing housing installed
  120
• 5.3 Removing and installing steel wheel bearing housing
  123
• 5.4 Removing and installing bonded rubber bush for steel wheel bearing housing
  125
• 5.5 Removing and installing upper links
  127
• 5.6 Renewing front and rear bonded rubber bushes for upper suspension link
  127
• 5.7 Removing and installing lower suspension link
  129
• 5.8 Repairing lower suspension link
  130
• 5.9 Removing and installing coupling rod for anti-roll bar
  133
• 6.1 Removing and installing wheel bearing
  137
• 6.2 Removing and installing aluminium wheel bearing housing
  140
• 6.4 Removing and installing coupling rod for anti-roll bar
  145
• 7 Repairing rear drive shaft
  147
• 7.1 Removing and installing drive shafts
  147
• 7.2 Repairing drive shaft with constant velocity joint
  148
• Self-levelling suspension
  153
• Wheels, tyres, vehicle geometry
  154
• 1 Appraisal of accident vehicles
  154
• 2 Fitting wheel and tyre
  155
• 2.1 Fitting wheels
  155
• 3 Wheel alignment
  156
• 3.1 General
  156
• 3.2 Vehicle alignment specifications, vehicles with front-wheel drive
  157
• 3.5 Test prerequisites
  161
• 3.6 Test preparations
  162
• 3.7 Assignment of adapters to running gear versions (for wheel alignment)
  164
• 3.8 Toe constant “S”
  164
• 3.9 Preparatory measures for checking/adjusting track constant “S”
  165
• 3.10 Vehicles pulling to one side; accident vehicles
  167
• 3.11 Averaging front axle camber
  168
• 3.12 Checking camber at rear wheels (front-wheel drive vehicles)
  169
• 3.13 Centralising toe setting at rear wheels (front-wheel drive vehicles)
  169
• 3.14 Adjusting rear axle camber, vehicles with four-wheel drive
  170
• 3.15 Adjusting rear axle toe, vehicles with four-wheel drive
  170
• 3.16 Adjusting toe constant “S”
  170
• 3.17 Adjusting toe at front axle
  171
• 4 Wheels, tyres
  172
• 4.1 Models with breakdown set
  172
• 4.2 Tyre sealant
  172
• 4.3 Removing a tyre
  172
• 4.4 Fitting a new tyre
  173
• 4.5 Tyre sealant disposal
  173
• 5 Instructions for changing or fitting wheels
  174
• 5.1 Fitting wheels
  175
• 6 Protecting wheel centring seat against corrosion
  176
• 7 Vibration due to wheels/tyres - causes and rectification
  177
• 7.1 Causes of vibration
  177
• 7.2 Balancing wheels
  177
• 7.3 Conducting a road test before balancing wheels
  177
• 7.4 Balancing wheels on stationary wheel balancing machine
  178
• 7.5 Vibration control system VAS 6230
  180
• 7.6 Finish balancer
  180
• 7.7 Radial and lateral run-out of wheels and tyres
  181
• 7.9 Checking radial and lateral run-out on wheel rim
  182
• 7.10 Matching
  183
• 7.11 Flat spots caused by storage or handling
  184
• Steering
  186
• 1 Appraisal of accident vehicles
  186
• 2 Steering column
  187
• 2.1 Removing and installing steering column
  187
• 2.2 Checking steering column for damage
  191
• 2.3 Removing and installing steering lock housing
  191
• 3 Steering rack
  194
• 3.1 Assembly overview - steering rack, LHD vehicles
  194
• 3.2 Assembly overview - steering rack, RHD vehicles
  195
• 3.3 Removing and installing track rods
  195
• 3.6 Removing and installing right-hand drive steering rack
  207
• 4 Dismantling and assembling power steering rack
  214
• 4.2 Dismantling and assembling power steering rack on vehicles with 5, 6 or 8-cylinder engine
  215
• 4.3 Checking power steering fluid level
  216
• 4.4 Bleeding steering system
  216
• 4.5 Checking steering system for leaks
  217
• 4.6 Adjusting power steering rack
  217
• 5 Vane pump, reservoir, hydraulic lines on vehicles with 4 or 5-cylinder engine
  219
• 5.1 Assembly overview for 4 or 5-cylinder engine
  219
• 5.2 Checking vane pump delivery pressure on 4 or 5-cylinder engine
  221
• 5.3 Removing and installing vane pump on 4 or 5-cylinder engine
  222
• 6.1 Assembly overview for 6-cylinder injection engine
  227
• 6.2 Checking vane pump delivery pressure, 6-cylinder injection engine
  229
• 6.3 Assembly overview of vane pump for 6-cylinder injection engine
  231
• 7.1 Assembly overview, 6-cylinder injection engine, 5 valves
  235
• 7.2 Checking vane pump delivery pressure, 6-cylinder injection engine, 5 valves
  237
• 7.3 Removing and installing power steering vane pump, 6-cylinder injection engine, 5 valves
  239
• 7.4 Assembly overview - vane pump, 6-cylinder injection engine, 5 valves
  242
• 8 Vane pump, reservoir, hydraulic lines on vehicles with V6 TDI engine
  244
• 8.1 Assembly overview of V6 TDI engine
  244
• 8.2 Checking vane pump delivery pressure, V6 TDI engine
  245
• 8.3 Removing and installing power steering vane pump for V6 TDI engine
  247
• 8.4 Assembly overview of vane pump for V6 TDI engine
  252
• 9.1 Assembly overview for 8-cylinder injection engine
  254
• 9.2 Checking vane pump delivery pressure, 8-cylinder injection engine
  256
• 9.3 Removing and installing power steering vane pump on 8-cylinder injection engine
  258