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 Raising wheel suspension to unladen position
  5
• 3 Overview - front axle
  7
• 4 Assembly overview: subframe, anti-roll bar, suspension links
  8
• 4.1 Assembly overview: front left vehicle level sender G78
  12
• 4.2 Removing and installing front left vehicle level sender G78
  12
• 4.3 Repairing thread in longitudinal member
  13
• 4.4 Fixing position of subframe and brackets
  14
• 4.5 Lowering subframe
  15
• 4.6 Removing and installing subframe without steering rack
  19
• 4.7 Removing and installing subframe with steering rack
  23
• 4.8 Repairing subframe
  28
• 4.9 Checking swivel joint
  40
• 4.10 Removing and installing swivel joint
  40
• 4.11 Removing and installing suspension link with mounting bracket
  44
• 4.13 Renewing bonded rubber bush for suspension link
  53
• 4.14 Renewing mounting bracket with suspension link bush
  56
• 4.15 Removing and installing anti-roll bar
  57
• 5 Assembly overview: wheel bearing
  64
• 5.1 Removing and installing wheel bearing unit
  65
• 5.2 Removing and installing wheel bearing housing
  68
• 6 Assembly overview: suspension strut
  74
• 6.1 Removing and installing suspension strut
  75
• 6.2 Repairing suspension strut
  82
• 7 Removing and installing drive shafts
  85
• 7.1 Loosening and tightening drive shaft hexagon bolt
  85
• 7.2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  86
• 7.4 Removing and installing drive shaft with constant velocity joint
  89
• 7.6 Removing and installing right drive shaft with (push-on) constant velocity slip joint
  97
• 7.7 Removing and installing drive shafts with triple roller joint AAR2600i
  103
• 7.8 Removing and installing drive shafts with triple roller joint AAR3300i
  107
• 7.9 Removing and installing intermediate shaft
  111
• 8 Repairing drive shaft - overview of drive shafts
  113
• 8.1 Heat shields for drive shafts
  115
• 9 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint
  116
• 9.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint
  118
• 9.2 Checking outer constant velocity joint
  122
• 9.3 Checking inner constant velocity joint
  123
• 10 Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on)
  126
• 10.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  129
• 10.2 Repairing intermediate shaft
  133
• 11 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on)
  136
• 11.1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint
  137
• 11.2 Checking outer constant velocity joint
  140
• 12 Assembly overview: drive shaft with triple roller joint AAR2600i
  142
• 12.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i
  144
• 13 Assembly overview: drive shaft with triple roller joint AAR3300i
  149
• 13.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i
  151
• Rear suspension
  156
• 1 Appraisal of accident vehicles
  156
• 2 Rear axle in unladen position
  157
• 3 Overview - rear axle
  160
• 4 Assembly overview: subframe, transverse links track rod
  161
• 4.1 Fixing position of subframe
  163
• 4.2 Lowering rear axle
  164
• 4.4 Removing and installing rear axle
  169
• 4.5 Removing and installing upper transverse link
  174
• 4.6 Removing and installing lower transverse link
  175
• 4.7 Removing and installing track rod
  177
• 5 Assembly overview: wheel bearing housing, trailing arm
  180
• 5.1 Removing and installing wheel bearing housing
  181
• 5.2 Renewing bonded rubber bush for wheel bearing housing
  184
• 5.3 Removing and installing wheel bearing/wheel hub unit
  187
• 5.4 Removing and installing wheel bearing pre-seal
  190
• 5.5 Removing and installing trailing arm with mounting bracket
  192
• 5.6 Repairing trailing arm
  196
• 6 Assembly overview: shock absorber, coil spring
  200
• 6.1 Removing and installing coil spring
  200
• 6.2 Removing and installing shock absorbers
  202
• 6.3 Repairing shock absorber
  204
• 7 Assembly overview: anti-roll bar
  206
• 7.1 Removing and installing anti-roll bar
  206
• 8 Assembly overview: subframe attachments, Touran BlueMotion
  209
• Self-levelling suspension
  210
• 1 Evaluating accident vehicles
  210
• 2 Components of adaptive chassis control DCC and fitting locations
  211
• 2.1 Shock absorber damping adjustment button E387
  212
• 2.2 Removing and installing front left and right body acceleration senders G341/G342
  212
• 2.3 Renewing bracket for front left/right body acceleration sender G341/G342
  213
• 2.5 Removing and installing front left/right vehicle level sender G78/G289
  216
• 2.6 Assembly overview: rear left vehicle level sender G76 for adaptive chassis control DCC
  217
• 2.8 Removing and installing electronically controlled damping control unit J250
  219
• 2.10 Basic setting of adaptive chassis control DCC
  220
• 2.11 Cable routing left front axle
  220
• 2.12 Cable routing right front axle
  222
• 2.13 Cable routing rear axle
  223
• 3 Assembly overview: suspension strut for adaptive chassis control DCC
  224
• 3.1 Removing and installing suspension strut for adaptive chassis control DCC
  226
• 4 Assembly overview: shock absorber for adaptive chassis control DCC
  235
• 4.1 Removing and installing rear body acceleration sender G343
  236
• 4.2 Removing and installing shock absorber for adaptive chassis control DCC
  237
• 4.3 Repairing shock absorber for adaptive chassis control DCC
  239
• Wheels, tyres, vehicle geometry
  242
• 1 Appraisal of accident vehicles
  242
• 2 Specified torques for wheel bolts
  243
• 3 Fitting wheel and tyre
  244
• 3.1 General information
  244
• 3.2 Fittings instructions
  244
• 4 Removing and fitting tyres (wheels with tyre pressure monitoring)
  246
• 4.2 Wheel change
  246
• 4.3 Pressing tyre off wheel rim
  247
• 4.4 Removing tyre from wheel
  248
• 4.5 Fitting tyre to wheel rim
  248
• 5 Removing and fitting tyres with run-flat properties to wheel rims
  250
• 5.1 Safety information
  250
• 5.2 Fittings instructions
  250
• 5.3 Pressing tyre off wheel rim
  251
• 5.4 Removing tyre from wheel
  252
• 5.5 Fitting tyre to wheel rim
  253
• 6 Tyre pressure monitor display
  256
• 6.1 System fault in the ABS system
  256
• 6.2 Perform basic settings
  257
• 7 Tyre pressure monitor
  258
• 7.1 Button behaviour
  258
• 7.2 Assembly overview: tyre pressure sensor
  259
• 7.3 Removing and installing tyre pressure sensor
  260
• 8 Vehicle alignment check
  262
• 8.1 General information
  262
• 8.2 Test requirements
  264
• 8.3 Test preparations
  264
• 8.4 Wheel alignment specifications
  265
• 8.5 Overview - wheel alignment procedure
  267
• 8.6 Correcting front axle camber
  268
• 8.7 Adjusting camber on rear axle
  269
• 8.8 Adjusting toe at rear axle
  271
• 8.9 Adjusting front axle toe
  272
• 8.10 Basic setting of steering angle sensor G85
  273
• 8.11 Vehicle data sticker
  273
• 9 Wheels, tyres
  274
• 9.1 Models with breakdown set
  274
• 9.2 Tyre sealant
  274
• 9.3 Removing a tyre
  274
• 9.4 Fitting a new tyre
  275
• 9.5 Tyre sealant disposal
  275
• 10 Instructions for changing or fitting wheels
  276
• 10.1 Fitting wheels
  277
• 11 Protecting wheel centring seat against corrosion
  278
• 12 Vibration due to wheels/tyres - causes and rectification
  279
• 12.1 Causes of rough running
  279
• 12.2 Balancing wheels
  279
• 12.3 Conducting a road test before balancing wheels
  279
• 12.4 Balancing wheels on stationary wheel balancing machine
  280
• 12.5 Vibration control system VAS 6230 A
  283
• 12.6 Finish balancer
  283
• 12.7 Radial and lateral runout of wheels and tyres
  284
• 12.9 Checking radial and lateral run-out on wheel rim
  285
• 12.10 Matching
  286
• 12.11 Flat spots caused by storage or handling
  287
• 13 Front camera for driver assist systems R242
  289
• 13.1 Adjusting front camera for driver assistance system R242
  289
• Steering
  297
• 1 Appraisal of accident vehicles
  297
• 2 General repair instructions
  298
• 2.1 Steering rack
  298
• 2.2 Gaskets and seals
  298
• 2.3 Nuts and bolts
  298
• 2.4 Electrical components
  299
• 2.5 Guided fault-finding, vehicle self-diagnosis and test instruments
  299
• 3 Assembly overview - steering columns up to model year 2010
  300
• 3.1 Removing and installing steering rack to model year 2010
  300
• 3.2 Removing and installing steering column to model year 2010
  303
• 3.3 After the following work, basic settings for steering angle sender G85 must be checked:
  308
• 3.4 Handling and transporting steering column, to model year 2010
  309
• 3.5 Checking steering column for damage
  310
• 3.6 Removing and installing mounting bracket with strut, to model year 2010
  310
• 4 Steering wheel, steering column, from model year 2011
  313
• 4.1 Assembly overview - airbag steering wheel, from model year 2011
  313
• 4.2 Removing and installing airbag and steering wheel
  313
• 4.3 Assembly overview - steering column, left-hand drive, from model year 2011
  315
• 4.4 Removing and installing steering column, left-hand drive, from model year 2011
  316
• 4.5 Assembly overview - steering column, right-hand drive, from model year 2011 . .
  321
• 4.7 Handling and transporting steering column, from model year 2011
  328
• 4.8 Checking steering column for damage
  329
• 5 Electromechanical steering rack, left-hand drive up to model year 2008
  330
• 7 Electromechanical steering rack, left-hand drive from model year 2011
  348
• 7.2 Removing and installing steering rack, left-hand drive vehicle (APA) from model year 2011
  349
• 8 Electromechanical steering rack, right-hand drive up to model year 2008
  357
• 9 Electromechanical steering rack, left-hand drive from model year 2009
  368
• 10 Differentiating between 1st and 2nd generation steering racks
  376
• 11 Differentiating between 2nd and 3rd generation steering racks
  377
• 12 Exchanging 1st generation steering rack for 2nd generation steering rack
  378
• 13 Repairing electromechanical 1st generation steering rack
  379
• 13.1 Removing and installing boot
  379
• 13.2 Removing and installing track rod
  381
• 14 Repairing electromechanical 2nd and 3rd generation steering racks
  385
• 14.1 Assembly overview: electromechanical steering rack
  385
• 14.2 Removing and installing boot
  386
• 14.3 Checking play, security and boots of track rod ends
  388
• 14.4 Removing and installing track rod
  388
• 15 Repairing electromechanical steering rack, left-hand drive (APA)
  392
• 15.1 Assembly overview: electromechanical steering rack, LHD vehicle
  392
• 15.2 Renewing bonded rubber bushes for power-assisted steering rack
  393
• 15.3 Removing and installing track rod
  395
• 15.4 Removing and installing track rod ball joint
  399
• 15.5 Removing and installing boot
  400
• 15.6 Checking play, security and boots of track rod ends
  403
• 15.7 Allocation of track rod ball joints
  403