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 bearing 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
  14
• 3.4 Repairing thread in longitudinal member
  15
• 3.5 Fixing position of subframe and brackets
  15
• 3.6 Lowering subframe
  17
• 3.7 Removing and installing subframe without steering rack
  21
• 3.8 Removing and installing subframe with steering rack
  23
• 3.9 Repairing subframe
  29
• 3.10 Checking swivel joint
  37
• 3.11 Removing and installing swivel joint
  38
• 3.12 Removing and installing suspension link with mounting bracket
  42
• 3.15 Renewing bonded rubber bush for suspension link
  54
• 3.16 Renewing mounting bracket with suspension link bush
  56
• 3.17 Removing and installing anti-roll bar
  57
• 4 Assembly overview: wheel bearing
  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 drive shaft hexagon bolt
  84
• 6.2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  85
• 6.4 Removing and installing drive shaft with constant velocity joint
  88
• 6.6 Removing and installing right drive shaft with (push-on) constant velocity slip joint
  96
• 6.7 Removing and installing drive shafts with triple roller joint AAR2600i
  102
• 6.8 Removing and installing drive shafts with triple roller joint AAR3300i
  106
• 7 Repairing drive shaft - overview of drive shafts
  111
• 7.1 Heat shields for drive shafts
  113
• 8 Assembly overview: drive shaft with VL100 constant velocity joint
  114
• 8.1 Dismantling and assembling drive shaft with VL100 constant velocity joint
  116
• 8.2 Checking outer constant velocity joint
  120
• 8.3 Checking inner constant velocity joint
  121
• 9 Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on)
  124
• 9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  126
• 10 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on)
  131
• 10.1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint
  132
• 10.2 Checking outer constant velocity joint
  135
• 11 Assembly overview: drive shaft with triple roller joint AAR2600i
  137
• 11.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i
  139
• 12 Assembly overview: drive shaft with triple roller joint AAR3300i
  144
• 12.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i
  146
• Rear suspension
  151
• 1 Appraisal of accident vehicles
  151
• 2 Repairing rear suspension (front-wheel drive)
  152
• 2.1 Overview - rear axle
  152
• 2.2 Rear axle in unladen position
  153
• 3 Assembly overview: subframe, transverse link, track rod (front-wheel drive)
  156
• 3.1 Fixing position of subframe
  158
• 3.2 Lowering rear axle
  159
• 3.3 Removing and installing rear axle
  161
• 3.4 Vehicle level sender for vehicles with automatic headlight range control
  165
• 3.5 Removing and installing rear left vehicle level sender G76
  166
• 3.6 Removing and installing upper transverse link
  167
• 3.7 Removing and installing lower transverse link
  168
• 3.8 Removing and installing track rod
  170
• 4 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)
  173
• 4.1 Removing and installing wheel bearing housing
  174
• 4.2 Renewing bonded rubber bush for wheel bearing housing
  178
• 4.3 Removing and installing wheel bearing/wheel hub unit
  180
• 4.4 Removing and installing trailing arm with mounting bracket
  183
• 4.5 Repairing trailing arm
  187
• 5 Assembly overview: shock absorber, coil spring (front-wheel drive)
  190
• 5.1 Removing and installing coil spring
  190
• 5.2 Removing and installing shock absorbers
  192
• 5.3 Repairing shock absorber
  194
• 6 Assembly overview: anti-roll bar (front-wheel drive)
  196
• 6.1 Removing and installing anti-roll bar
  196
• 7 Removing and installing radius rods
  199
• 7.1 Removing radius rods
  199
• 7.2 Installing radius rods
  199
• Self-levelling suspension
  200
• 1 Appraisal of accident vehicles
  200
• 2 Components of adaptive chassis control DCC and fitting locations
  201
• 2.1 Shock absorber damping adjustment button E387
  202
• 2.2 Removing and installing front left body acceleration sender G341
  202
• 2.3 Removing and installing front right body acceleration sender G342
  203
• 2.4 Renewing bracket for front left/right body acceleration sender G341/G342
  204
• 2.6 Removing and installing front left/right vehicle level sender G78/G289
  207
• 2.9 Removing and installing electronically controlled damping control unit J250
  210
• 2.10 Basic setting of adaptive chassis control DCC
  211
• 2.11 Cable routing left front axle
  211
• 2.12 Cable routing right front axle
  213
• 2.13 Cable routing rear axle
  214
• 3 Assembly overview: suspension strut for adaptive chassis control DCC
  215
• 3.1 Removing and installing suspension strut for adaptive chassis control DCC
  217
• 4 Assembly overview: shock absorber for adaptive chassis control DCC (front-wheel drive)
  224
• 4.1 Removing and installing rear body acceleration sender G343 (front-wheel drive)
  225
• 4.3 Repairing shock absorber for adaptive chassis control DCC (front-wheel drive)
  228
• Wheels, tyres, vehicle geometry
  231
• 1 Appraisal of accident vehicles
  231
• 2 Specified torques for wheel bolts
  232
• 3 Fitting wheel and tyre
  233
• 3.1 General information
  233
• 3.2 Fittings instructions
  233
• 4 Removing and fitting tyres (wheels with tyre pressure monitoring)
  235
• 4.2 Wheel change
  235
• 4.3 Pressing tyre off wheel rim
  236
• 4.4 Removing tyre from wheel
  237
• 4.5 Fitting tyre to wheel rim
  237
• 5 Removing and fitting tyres with run-flat properties to wheel rims
  239
• 5.1 Safety notes
  239
• 5.2 Pressing tyre off wheel rim
  239
• 5.3 Removing tyre from wheel
  240
• 5.4 Fitting tyre to wheel rim
  241
• 6 Self-sealing tyres “ContiSeal”
  244
• 6.1 Explanations about ContiSeal tyres
  244
• 6.2 Handling ContiSeal tyres
  245
• 7 Tyre pressure monitor display
  246
• 7.1 System fault in the ABS system
  246
• 7.2 Performing basic setting
  247
• 8 Tyre pressure monitoring system (TPMS)
  248
• 8.1 Button behaviour
  248
• 8.2 Assembly overview: tyre pressure sensor
  249
• 8.3 Removing and installing tyre pressure sensor
  250
• 9 Vehicle alignment check
  252
• 9.1 General information
  252
• 9.2 Prerequisites for testing
  254
• 9.3 Test preparations
  254
• 9.4 Wheel alignment specifications
  255
• 9.5 Overview - wheel alignment procedure
  257
• 9.6 Correcting front axle camber
  258
• 9.7 Adjusting camber on rear axle
  260
• 9.8 Adjusting toe at rear axle
  261
• 9.9 Adjusting front axle toe
  262
• 9.10 Basic setting of steering angle sensor G85
  263
• 9.11 Vehicle data sticker
  263
• 10 Wheels, tyres
  264
• 10.1 Models with breakdown set
  264
• 10.2 Tyre sealant
  264
• 10.3 Removing a tyre
  264
• 10.4 Fitting a new tyre
  265
• 10.5 Tyre sealant disposal
  265
• 10.6 Alloy wheels with metal valves
  265
• 11 Instructions for changing or fitting wheels
  267
• 11.1 Fitting wheels
  268
• 12 Protecting wheel centring seat against corrosion
  269
• 13 Vibration due to wheels/tyres - causes and rectification
  270
• 13.1 Causes of rough running
  270
• 13.2 Balancing wheels
  270
• 13.3 Conducting a road test before balancing wheels
  270
• 13.4 Balancing wheels on stationary wheel balancing machine
  271
• 13.5 Vibration control system VAS 6230 A
  274
• 13.6 Finish balancer
  274
• 13.7 Radial and lateral runout of wheels and tyres
  275
• 13.9 Checking radial and lateral run-out on wheel rim
  276
• 13.10 Matching
  277
• 13.11 Flat spots caused by storage or handling
  278
• Steering
  280
• 1 Appraisal of accident vehicles
  280
• 2 General repair instructions
  281
• 2.1 Steering rack
  281
• 2.2 Gaskets and seals
  281
• 2.3 Nuts and bolts
  281
• 2.4 Electrical components
  282
• 2.5 Guided Fault Finding, vehicle self-diagnosis and Test Instruments
  282
• 3 Steering wheel
  283
• 3.1 Removing and installing steering wheel
  283
• 4 Steering columns up to model year 2008
  286
• 4.1 Assembly overview: steering column
  286
• 4.2 Removing and installing steering column
  286
• 4.4 Handling and transporting steering column
  292
• 4.5 Checking steering column for damage
  294
• 4.6 Removing and installing mounting bracket
  294
• 4.7 Removing and installing strut
  296
• 5 Steering columns from model year 2009
  298
• 5.1 Assembly overview: steering column, left-hand drive
  298
• 5.2 Removing and installing steering column, left-hand drive vehicle
  298
• 5.3 Assembly overview: steering column, right-hand drive
  305
• 5.4 Removing and installing steering column, right-hand drive vehicle
  306
• 5.5 Handling and transporting steering column
  311
• 5.6 Checking steering column for damage
  312
• 6 Electromechanical steering rack up to model year 2008
  314
• 7 Electromechanical steering rack from model year 2009
  335
• 8 Differentiating between 2nd and 3rd generation steering racks
  353
• 9 Repairing electromechanical 2nd and 3rd generation steering racks
  354
• 9.1 Assembly overview: electromechanical steering rack
  354
• 9.2 Removing and installing bellows
  355
• 9.3 Removing and installing track rod
  357