Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Checklist for evaluating running gear of accident vehicles
  1
• 2 General information
  3
• Front suspension
  4
• 1 Appraisal of accident vehicles
  4
• 2 Servicing front suspension
  5
• 2.1 Overview - front axle
  5
• 2.2 Raising wheel suspension to unladen position
  6
• 3 Subframe, anti-roll bar, suspension links
  9
• 3.1 Assembly overview: subframe, anti-roll bar, suspension links
  9
• 3.2 Assembly overview: front left vehicle level sender G78
  13
• 3.3 Removing and installing front left vehicle level sender G78
  13
• 3.4 Repairing thread in longitudinal member
  14
• 3.5 Fixing position of subframe
  15
• 3.6 Lowering subframe
  16
• 3.7 Removing and installing subframe without steering rack
  20
• 3.8 Removing and installing subframe with steering rack
  24
• 3.9 Repairing subframe
  29
• 3.10 Checking swivel joint
  41
• 3.11 Removing and installing swivel joint
  41
• 3.12 Removing and installing suspension link with mounting bracket
  45
• 3.14 Renewing bonded rubber bush for suspension link
  54
• 3.15 Renewing mounting bracket with suspension link bush
  56
• 3.16 Removing and installing anti-roll bar
  57
• 4 Assembly overview - wheel bearings
  63
• 4.1 Removing and installing wheel bearing unit
  65
• 4.2 Removing and installing wheel bearing housing
  67
• 5 Assembly overview: suspension strut
  73
• 5.1 Removing and installing suspension strut
  74
• 5.2 Repairing suspension strut
  81
• 6 Removing and installing drive shafts
  84
• 6.1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  84
• 6.3 Removing and installing drive shaft with constant velocity joint
  87
• 6.4 Removing and installing drive shafts with triple roller joint AAR3300i (bolted on)
  90
• 7 Repairing drive shaft - overview of drive shafts
  101
• 7.1 Heat shields for drive shafts
  102
• 8 Assembly overview: drive shaft with VL100 constant velocity joint
  103
• 8.1 Dismantling and assembling drive shaft with VL100 constant velocity joint
  105
• 8.2 Checking outer constant velocity joint
  109
• 8.3 Checking inner constant velocity joint
  110
• 9 Assembly overview: drive shaft with VL107 constant velocity joint
  113
• 9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  115
• 11 Assembly overview: drive shaft with triple roller joint AAR3300i (pushed onto stub shaft)
  128
• Rear suspension
  133
• 1 Appraisal of accident vehicles
  133
• 2 Repairing rear suspension
  134
• 2.1 Overview - rear axle
  134
• 2.2 Rear axle in unladen position
  135
• 3 Assembly overview: subframe, transverse links track rod
  137
• 3.1 Fixing position of subframe
  138
• 3.2 Lowering rear axle
  140
• 3.3 Assembly overview: rear left vehicle level sender G76
  143
• 3.4 Removing and installing rear left vehicle level sender G76
  143
• 3.5 Removing and installing rear axle
  144
• 3.6 Removing and installing upper transverse link
  148
• 3.7 Removing and installing lower transverse link
  150
• 3.8 Removing and installing track rod
  151
• 4 Assembly overview: wheel bearing housing, trailing arm
  155
• 4.1 Removing and installing wheel bearing housing
  156
• 4.2 Renewing bonded rubber bush for wheel bearing housing
  160
• 4.3 Removing and installing wheel bearing/wheel hub unit
  162
• 4.4 Removing and installing trailing arm with mounting bracket
  165
• 4.5 Repairing trailing arm
  169
• 5 Assembly overview: shock absorber, coil spring
  172
• 5.1 Removing and installing coil spring
  172
• 5.2 Removing and installing shock absorbers
  174
• 5.3 Repairing shock absorber
  176
• 6 Assembly overview: anti-roll bar
  178
• 6.1 Removing and installing anti-roll bar
  178
• Self-levelling suspension
  181
• 1 Appraisal of accident vehicles
  181
• 2 Components of adaptive chassis control DCC and fitting locations
  182
• 2.1 Shock absorber damping adjustment button E387
  183
• 2.2 Removing and installing front left and right body acceleration senders G341/G342
  183
• 2.3 Renewing bracket for front left/right body acceleration sender G341/G342
  184
• 2.5 Removing and installing front left/right vehicle level sender G78/G289
  187
• 2.6 Assembly overview: rear left vehicle level sender G76 for adaptive chassis control DCC
  188
• 2.8 Removing and installing electronically controlled damping control unit J250
  190
• 2.9 Basic setting of adaptive chassis control DCC
  191
• 2.10 Cable routing left front axle
  191
• 2.11 Cable routing right front axle
  193
• 2.12 Cable routing rear axle
  194
• 3 Assembly overview: suspension strut for adaptive chassis control DCC
  195
• 3.1 Removing and installing suspension strut for adaptive chassis control DCC
  197
• 4 Assembly overview: shock absorber for adaptive chassis control DCC
  206
• 4.1 Removing and installing rear body acceleration sender G343
  207
• 4.2 Removing and installing shock absorber for adaptive chassis control DCC
  208
• 4.3 Repairing shock absorber for adaptive chassis control DCC
  210
• Wheels, tyres, vehicle geometry
  213
• 1 Appraisal of accident vehicles
  213
• 2 Specified torque for wheel bolts
  214
• 3 Fitting wheel and tyre
  215
• 3.1 General information
  215
• 3.2 Fittings instructions
  215
• 3.3 Fitting tyre
  216
• 4 Removing and fitting tyres (wheels with tyre pressure monitoring)
  217
• 4.2 Wheel change
  217
• 4.3 Pressing tyre off wheel rim
  218
• 4.4 Removing tyre from wheel
  219
• 4.5 Fitting tyre to wheel rim
  219
• 5 Removing and fitting tyres with run-flat properties to wheel rims
  221
• 5.1 Safety information
  221
• 5.2 Pressing tyre off wheel rim
  221
• 5.3 Removing tyre from wheel
  222
• 5.4 Fitting tyre to wheel rim
  223
• 6 Tyre pressure monitor display
  226
• 6.1 General information
  226
• 6.2 System fault in the ABS system
  227
• 6.3 Performing basic setting
  227
• 7 Tyre pressure monitoring system (TPMS)
  228
• 7.1 Button behaviour
  228
• 7.2 Assembly overview: tyre pressure sensor
  229
• 7.3 Removing and installing tyre pressure sensor
  230
• 8 Vehicle alignment check
  232
• 8.1 General information
  232
• 8.2 Prerequisites for testing
  234
• 8.3 Test preparations
  234
• 8.4 Wheel alignment specifications
  235
• 8.5 Overview - wheel alignment procedure
  236
• 8.6 Correcting front axle camber
  237
• 8.7 Adjusting camber on rear axle
  239
• 8.8 Adjusting toe at rear axle
  241
• 8.9 Adjusting front axle toe
  241
• 8.10 Basic setting of steering angle sensor G85
  243
• 8.11 Vehicle data sticker
  243
• 9 Wheels, tyres
  244
• 9.1 Models with breakdown set
  244
• 9.2 Tyre sealant
  244
• 9.3 Removing a tyre
  244
• 9.4 Fitting a new tyre
  245
• 9.5 Tyre sealant disposal
  245
• 10 Instructions for changing or fitting wheels
  246
• 10.1 Fitting wheels
  247
• 11 Protecting wheel centring seat against corrosion
  248
• 12 Vibration due to wheels/tyres - causes and rectification
  249
• 12.1 Causes of rough running
  249
• 12.2 Balancing wheels
  249
• 12.3 Conducting a road test before balancing wheels
  249
• 12.4 Balancing wheels on stationary wheel balancing machine
  250
• 12.5 Vibration control system VAS 6230 A
  253
• 12.6 Finish balancer
  253
• 12.7 Radial and lateral runout of wheels and tyres
  254
• 12.9 Checking radial and lateral run-out on wheel rim
  255
• 12.10 Matching
  256
• 12.11 Flat spots caused by storage or handling
  257
• Steering
  259
• 1 Appraisal of accident vehicles
  259
• 2 General repair instructions
  260
• 2.1 Steering rack
  260
• 2.2 Gaskets and seals
  260
• 2.3 Nuts and bolts
  260
• 2.4 Electrical components
  261
• 2.5 Guided Fault Finding, vehicle self-diagnosis and Test Instruments
  261
• 3 Steering wheel, steering column
  262
• 3.1 Removing and installing steering wheel
  262
• 3.2 Assembly overview: steering column
  265
• 3.3 Removing and installing steering column, left-hand drive vehicle
  265
• 3.4 Assembly overview: steering column, right-hand drive
  272
• 3.5 Removing and installing steering column, right-hand drive vehicle
  273
• 3.7 Handling and transporting steering column
  279
• 3.8 Checking steering column for damage
  280
• 4 Electromechanical steering rack
  281
• 4.1 Assembly overview - electromechanical steering rack, left-hand drive
  281
• 4.2 Assembly overview - electromechanical steering rack, right-hand drive
  283
• 4.3 Removing and installing steering rack, left-hand drive vehicle
  284
• 4.4 Removing and installing steering rack, right-hand drive vehicle
  291
• 5 Repairing electromechanical steering rack
  300
• 5.1 Assembly overview: electromechanical steering rack
  300
• 5.2 Removing and installing boot
  301
• 5.3 Removing and installing track rod
  303