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 Evaluating accident vehicles
  4
• 2 Raising wheel suspension to unladen position
  5
• 3 Overview - front axle
  7
• 4 Assembly overview: subframe
  9
• 4.1 Repairing thread in longitudinal member
  10
• 4.2 Fixing position of subframe
  10
• 4.3 Lowering subframe
  13
• 4.4 Removing and installing subframe without steering rack
  17
• 4.5 Removing and installing subframe with hydraulic steering rack
  20
• 4.6 Removing and installing subframe with electromechanical steering rack
  27
• 4.7 Repairing subframe
  31
• 5 Assembly overview: front wheel suspension, suspension link
  41
• 5.1 Checking swivel joint
  42
• 5.2 Removing and installing swivel joint
  43
• 5.3 Removing and installing suspension link
  47
• 5.5 Renewing front bonded rubber bush for suspension link
  53
• 5.6 Renewing rear bonded rubber bush for suspension link
  55
• 6 Assembly overview: wheel bearing
  58
• 6.1 Removing and installing wheel bearing unit
  59
• 6.2 Removing and installing wheel bearing housing
  62
• 7 Assembly overview: anti-roll bar
  69
• 7.1 Removing and installing anti-roll bar
  69
• 8 Assembly overview: suspension strut
  74
• 8.1 Removing and installing suspension strut
  75
• 8.2 Repairing suspension strut
  81
• 9 Removing and installing drive shafts
  84
• 9.1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  84
• 9.3 Removing and installing drive shaft with constant velocity joint
  87
• 9.4 Removing and installing right drive shaft with (push-on) constant velocity slip joint
  90
• 9.5 Removing and installing drive shafts with triple roller joint AAR2600i
  96
• 9.6 Removing and installing drive shafts with triple roller joint AAR3300i
  100
• 10 Repairing drive shafts - overview of drive shafts
  105
• 10.1 Heat shield for drive shafts
  106
• 11 Assembly overview: drive shaft with VL100 constant velocity joint
  107
• 11.1 Dismantling and assembling drive shaft with VL100 constant velocity joint
  109
• 11.2 Checking outer constant velocity joint
  113
• 11.3 Checking inner constant velocity joint
  114
• 12 Assembly overview: drive shaft with VL107 constant velocity joint
  117
• 12.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  119
• 13 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on)
  124
• 13.1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint
  125
• 14 Assembly overview: drive shaft with triple roller joint AAR2600i
  129
• 14.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i
  131
• 15 Assembly overview: drive shaft with triple roller joint AAR3300i
  136
• 15.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i
  138
• Rear suspension
  144
• 1 Evaluating accident vehicles
  144
• 2 Rear axle in unladen position (torsion beam rear axle)
  145
• 3 Overview of rear axle (torsion beam rear axle)
  147
• 4 Assembly overview: axle beam, subframe, cross piece (torsion beam rear axle)
  149
• 4.1 Removing and installing axle assembly
  150
• 4.2 Removing and installing bonded rubber bush for axle beam
  154
• 4.3 Removing and installing cross piece
  158
• 4.4 Removing and installing bonded rubber bush for cross piece
  160
• 5 Assembly overview - plate for axle beam, torsion beam rear axle
  163
• 5.1 Removing plate for axle beam
  163
• 5.2 Installing plate for axle beam
  164
• 6 Assembly overview: wheel suspension (torsion beam rear axle)
  170
• 6.1 Removing and installing coil spring
  171
• 7 Assembly overview: shock absorbers (torsion beam rear axle)
  173
• 7.1 Removing and installing shock absorbers
  174
• 8 Assembly overview: wheel bearings, drum brake (torsion beam rear axle)
  176
• 8.1 Removing and installing wheel hub with wheel bearing, vehicles with drum brakes
  177
• 9 Assembly overview: wheel bearings, disc brake (torsion beam rear axle)
  181
• 10 Rear axle in unladen position (multi-link rear suspension)
  185
• 11 Overview of rear axle (multi-link rear suspension)
  188
• 12.1 Assembly overview: rear left vehicle level sender G76
  191
• 12.2 Removing and installing rear left vehicle level sender G76
  191
• 12.3 Fixing position of subframe
  192
• 12.4 Lowering rear axle
  193
• 12.5 Removing and installing rear axle
  196
• 12.6 Removing and installing upper transverse link
  199
• 12.7 Removing and installing lower transverse link
  201
• 12.8 Removing and installing track rod
  203
• 13.1 Removing and installing wheel bearing housing
  207
• 13.2 Renewing bonded rubber bush for wheel bearing housing
  210
• 13.3 Removing and installing wheel bearing/wheel hub unit
  213
• 13.4 Removing and installing trailing arm with mounting bracket
  216
• 13.5 Repairing trailing arm
  220
• 14 Assembly overview: shock absorber, coil spring (multi-link rear suspension)
  224
• 14.1 Removing and installing coil spring
  224
• 14.2 Removing and installing shock absorbers
  226
• 14.3 Repairing shock absorber
  228
• 15 Assembly overview: anti-roll bar (multi-link rear suspension)
  230
• 15.1 Removing and installing anti-roll bar
  230
• 16 Assembly overview: subframe attachments, BlueMotion vehicles
  233
• 16.1 Removing and installing shield for rear axle
  234
• Wheels, tyres, vehicle geometry
  236
• 1 Evaluating accident vehicles
  236
• 2 Specified torque for fitting wheels
  237
• 3 Fitting wheel and tyre
  238
• 3.1 General information
  238
• 3.2 Fittings instructions
  238
• 4 Removing and fitting tyres (wheels with tyre pressure monitoring)
  240
• 4.2 Wheel change
  240
• 4.3 Fittings instructions
  241
• 4.4 Pressing tyre off wheel rim
  242
• 4.5 Removing tyre from wheel
  243
• 4.6 Fitting tyre to wheel rim
  243
• 5 Removing and fitting tyres with run-flat properties to wheel rims
  245
• 5.1 Safety information
  245
• 5.2 Fittings instructions
  245
• 5.3 Pressing tyre off wheel rim
  246
• 5.4 Removing tyre from wheel
  247
• 5.5 Fitting tyre to wheel rim
  248
• 6 Tyre pressure monitor display
  251
• 6.1 General information
  251
• 7 Tyre Pressure Monitoring System (TPMS)
  253
• 7.1 Assembly overview: tyre pressure sensor
  253
• 7.2 Removing and installing tyre pressure sensor
  254
• 8 Vehicle alignment check
  255
• 8.1 General information for vehicles with torsion beam rear axle
  255
• 8.2 General information for vehicles with multi-link rear suspension
  257
• 8.3 Conditions for testing
  258
• 8.4 Checking trailing arm of axle beam (torsion beam rear axle) using VAS 241 001
  259
• 8.5 Checking trailing arm of axle beam (torsion beam rear axle) using VAS 801
  261
• 8.6 Test preparations
  264
• 8.7 Vehicle alignment specifications for vehicles with torsion beam rear axle
  264
• 8.8 Vehicle alignment specifications for vehicles with multi-link rear suspension
  266
• 8.9 Transverse vehicle inclination “zero position”
  268
• 8.10 Overview - wheel alignment procedure
  268
• 8.11 Correcting front axle camber
  269
• 8.12 Checking torsion beam rear axle camber
  271
• 8.13 Adjusting multi-link rear suspension camber
  271
• 8.14 Checking torsion beam rear axle toe
  272
• 8.15 Adjusting multi-link rear suspension toe
  273
• 8.16 Adjusting front axle toe
  273
• 8.17 Basic setting of steering angle sensor G85
  274
• 8.18 Vehicle data sticker
  274
• 9 Wheels, tyres
  276
• 9.1 Models with breakdown set
  276
• 9.2 Removing a tyre
  276
• 9.3 Fitting a new tyre
  276
• 9.4 Tyre sealant disposal
  277
• 10 Instructions for changing or fitting wheels
  278
• 10.1 Fitting wheels
  279
• 11 Protecting wheel centring seat against corrosion
  280
• 12 Vibration due to wheels/tyres - causes and rectification
  281
• 12.1 Causes of rough running
  281
• 12.2 Balancing wheels
  281
• 12.3 Conducting a road test before balancing wheels
  281
• 12.4 Balancing wheels on stationary wheel balancing machine
  282
• 12.5 Vibration control system VAS 6230 A
  284
• 12.6 Finish balancer
  284
• 12.7 Radial and lateral runout of wheels and tyres
  285
• 12.9 Checking radial and lateral run-out on wheel rim
  286
• 12.10 Matching
  287
• 12.11 Flat spots caused by storage or handling
  288
• Steering
  290
• 1 Evaluating accident vehicles
  290
• 2 General repair instructions
  291
• 2.1 Steering rack
  291
• 2.2 Gaskets and seals
  291
• 2.3 Nuts and bolts
  291
• 2.4 Electrical components
  292
• 2.5 Guided Fault Finding, vehicle self-diagnosis and Test Instruments
  292
• 3 Assembly overview - airbag and steering wheel
  293
• 3.1 Removing and installing airbag and steering wheel
  293
• 4 Assembly overview: steering column, left-hand drive
  296
• 4.1 Removing and installing steering column
  296
• 4.2 Handling and transporting steering column
  304
• 4.3 Checking steering column for damage
  305
• 5 Assembly overview: steering column, right-hand drive
  307
• 5.1 Removing and installing steering column, right-hand drive vehicle
  307
• 5.2 Handling and transporting steering column
  316
• 5.3 Checking steering column for damage
  317
• 6 Electromechanical steering rack, LHD vehicle
  318
• 6.1 Assembly overview - electromechanical steering rack for LHD vehicle
  318
• 6.2 Removing and installing steering rack, left-hand drive vehicle
  320
• 7 Electromechanical steering rack, RHD vehicle
  328
• 7.1 Assembly overview - electromechanical steering rack for RHD vehicle
  328
• 7.2 Removing and installing steering rack, right-hand drive vehicle
  329
• 8 Repairing electromechanical steering rack
  336
• 8.1 Assembly overview: electromechanical steering rack
  336
• 8.2 Removing and installing track rod
  337
• 8.3 Removing and installing track rod ball joint
  340
• 8.4 Removing and installing boot
  341
• 8.5 Checking play, security and boots of track rod ends
  344
• 8.6 Checking and adjusting track rod length
  344
• 8.7 Allocation of track rod ball joints
  345
• 9 Assembly overview: hydraulic power steering
  346
• 9.1 Removing and installing power-assisted steering rack
  347
• 10 Repairing hydraulic power-assisted steering rack
  353
• 10.1 Assembly overview: power-assisted steering rack
  353
• 10.2 Removing and installing track rod
  354
• 10.3 Removing and installing track rod ball joint
  357
• 10.4 Removing and installing boot
  358
• 10.5 Checking play, security and boots of track rod ends
  360
• 10.6 Checking and adjusting left track rod length
  360
• 10.7 Allocation of track rod ball joints
  361
• 11 Vane pump, 4-cylinder petrol engine
  362
• 11.1 Assembly overview: vane pump, 4-cylinder petrol engine
  362
• 11.2 Removing and installing vane pump, 4-cylinder petrol engine
  363
• 12 Vane pump, 5-cylinder petrol engine
  366
• 12.1 Checking vane pump delivery pressure, 5-cylinder petrol engine
  366
• 12.2 Assembly overview: vane pump, 5-cylinder petrol engine
  369
• 12.3 Removing and installing vane pump, 5-cylinder petrol engine
  370
• 13 Assembly overview: hydraulic lines, 4-cylinder petrol engine
  374
• 14 Assembly overview: hydraulic lines, 5-cylinder petrol engine
  376
• 15 Assembly overview: power steering reservoir, 4-cylinder petrol engine
  378
• 16 Assembly overview: power steering reservoir, 5-cylinder petrol engine
  379
• 17 Checking power steering fluid level
  380
• 18 Bleeding steering system and checking for leaks
  381
• 18.1 Bleeding steering system
  381
• 18.2 Check steering system for leaks
  381