Running gear, axles, steering

Kapitelübersicht

• Technical data
  1
• 1 Check list for assessing the running gear on accident vehicles
  1
• 2 General notes
  3
• Front suspension
  4
• 1 Appraisal of accident vehicles
  4
• 2 Repairing front suspension
  5
• 2.1 Overview - front axle
  5
• 2.2 Raising wheel suspension to unladen position
  6
• 3 I - Assembly overview, subframe, anti-roll bar and suspension link
  8
• 3.1 Repairing threads in longitudinal member
  10
• 3.2 Fixing subframe in position
  10
• 3.3 Checking swivel joint
  12
• 3.4 Removing and installing swivel joint
  12
• 3.5 Installation position of swivel joints
  15
• 3.6 Removing and installing suspension link
  15
• 3.7 Removing and installing bracket
  17
• 3.8 Renewing bonded rubber bush for bracket
  19
• 3.9 Removing and installing subframe
  21
• 3.10 Removing and installing anti-roll bar, vehicles with power-assisted steering
  24
• 4 II - Assembly overview - wheel bearing
  26
• 5 III - Assembly overview - suspension strut
  38
• 5.1 Vehicle data sticker
  39
• 5.2 Removing and installing suspension strut
  39
• 5.3 Repairing front coil spring suspension strut
  43
• 6 Repairing drive shafts
  46
• 6.1 Removing and installing drive shafts
  46
• 7 IV - Repairing drive shaft with constant velocity joint
  49
• 7.1 Checking outer constant velocity joint
  54
• 7.2 Checking inner constant velocity joint
  55
• 8 V - Repairing drive shaft with triple roller joint
  57
• 8.1 Dismantling and assembling triple roller joint
  60
• Rear suspension
  64
• 1 Appraisal of accident vehicles
  64
• 2 Repairing rear axle
  65
• 2.1 Removing and installing rear axle
  65
• 2.2 Assembly overview - rear axle beam, drum brake
  68
• 2.3 Assembly overview - rear axle beam, disc brake
  71
• 2.4 Removing and installing bonded rubber bush
  73
• 2.5 Removing and installing spring
  76
• 2.6 Removing and installing shock absorber
  77
• 2.7 Assembly overview - shock absorber on vehicle with front wheel drive
  79
• 3 Repairing wheel bearing, drum brake
  82
• 3.1 Assembly overview - wheel bearing
  82
• 3.2 Removing and installing wheel bearing/hub unit on vehicles with drum brakes
  83
• 4 Repairing wheel bearing (disc brake)
  85
• 4.1 Assembly overview - wheel bearing
  85
• 4.2 Removing and installing wheel bearing/wheel hub on vehicles with disc brakes
  86
• Wheels, tyres, vehicle geometry
  89
• 1 Appraisal of accident vehicles
  89
• 2 Specified torques for wheel bolts
  90
• 3 Removing and fitting tyres with run-flat capability to wheel rims
  91
• 3.1 Pressing tyre off wheel rim
  91
• 3.2 Removing tyre from wheel
  92
• 3.3 Fitting tyre to wheel rim
  93
• 4 Tyre Pressure Monitor Display (TPM)
  95
• 5 Wheel alignment
  97
• 5.1 General
  97
• 5.2 Test prerequisites
  98
• 5.3 Test preparations
  99
• 5.4 Vehicle data sticker
  99
• 5.5 Wheel alignment specifications
  99
• 5.6 Transverse vehicle inclination “zero position”
  101
• 5.7 Overview - wheel alignment procedure
  101
• 5.8 Adjusting front axle camber
  101
• 5.9 Check rear axle camber
  103
• 5.10 Check rear axle toe
  103
• 5.11 Adjusting front axle toe
  103
• 5.12 Checking left and right wheel lock
  103
• 6 Wheels, tyres
  105
• 6.1 Vehicles with breakdown set
  105
• 6.2 Tyre sealant
  105
• 6.3 Removing a tyre
  105
• 6.4 Fitting a new tyre
  106
• 6.5 Disposal of tyre sealant
  106
• 7 Protecting wheel centring seat against corrosion
  107
• Steering
  108
• 1 Appraisal of accident vehicles
  108
• 2 Electrical/electronic components and fitting locations
  109
• 3 Steering column
  110
• 3.1 Removing and installing steering column
  110
• 3.2 Checking steering column for damage
  114
• 3.3 Removing and installing steering lock housing
  115
• 3.4 Assembly overview - cross member for steering column
  116
• 3.5 Removing and installing locking cable for ignition with key removal lock
  117
• 3.6 Checking ignition key removal lock
  118
• 3.7 Removing and installing mounting bracket
  118
• 3.8 Removing and installing strut
  119
• 4 Repairing mechanical (manual) steering box
  121
• 4.1 Assembly overview - mechanical (manual) steering box
  121
• 4.2 Removing and installing mechanical (manual) steering box
  122
• 4.3 Dismantling and assembling mechanical (manual) steering box
  125
• 4.4 Removing and installing track rod
  127
• 4.5 Checking play, tightness and bellows of track rod ball joints
  128
• 4.6 Checking and adjusting left track rod length
  128
• 4.7 Allocation of track rod ball joints
  129
• 4.8 Determining centre position of steering rack
  129
• 4.9 Adjusting steering box
  129
• 5 Repairing electrohydraulic power-assisted steering box (TRW)
  131
• 5.1 Assembly overview - power-assisted steering box (TRW)
  131
• 5.2 Removing and installing power-assisted steering box (TRW)
  132
• 5.3 Removing and installing power steering sensor G250 (TRW)
  138
• 5.4 Dismantling and assembling power-assisted steering box (TRW)
  141
• 5.5 Removing and installing track rod (TRW)
  143
• 5.6 Checking play, tightness and bellows of track rod ball joints (TRW)
  144
• 5.7 Checking and adjusting left track rod length (TRW)
  144
• 5.8 Allocation of track rod ball joints (TRW)
  145
• 5.9 Determining centre position of rack (TRW)
  145
• 5.10 Adjusting steering box (TRW)
  146
• 5.11 Checking delivery pressure of motor/pump unit (TRW)
  146
• 5.12 Removing and installing motor/pump unit (TRW)
  149
• 5.13 Assembly overview - motor/pump unit (TRW)
  153
• 5.14 Renewing reservoir of motor/pump unit (TRW)
  154
• 6 Repairing electrohydraulic power-assisted steering box (Koyo)
  157
• 6.1 Assembly overview - power-assisted steering box (Koyo)
  157
• 6.2 Removing and installing power-assisted steering box (Koyo)
  158
• 6.3 Removing and installing power steering sensor G250 ( Koyo)
  164
• 6.4 Dismantling and assembling power-assisted steering box (Koyo)
  167
• 6.5 Removing and installing track rod (Koyo)
  169
• 6.6 Checking play, tightness and bellows of track rod ball joints (Koyo)
  170
• 6.7 Checking and adjusting left track rod length (Koyo)
  170
• 6.8 Allocation of track rod ball joints (Koyo)
  171
• 6.9 Determining centre position of rack (Koyo)
  171
• 6.10 Adjusting steering box (Koyo)
  171
• 6.11 Checking delivery pressure of motor/pump unit (Koyo)
  172
• 6.12 Removing and installing motor/pump unit (Koyo)
  174
• 6.13 Assembly overview - motor/pump unit (Koyo)
  178
• 6.14 Renewing reservoir of motor/pump unit (Koyo)
  179
• 7 Bleeding steering system, checking for leaks and checking fluid level
  182
• 7.1 Bleeding steering system
  182
• 7.2 Checking steering system for leaks
  182
• 7.3 Checking hydraulic fluid level of power-assisted steering
  183