Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on subframe
  1
• 2 Evaluating accident vehicles
  2
• 2.1 Check list for evaluating running gear on accident vehicles
  2
• 3 General information
  4
• 3.1 Tyre types
  4
• 3.2 Vehicle data sticker
  4
• 3.3 General notes on tyre pressure indicator
  4
• 4 Repair instructions
  6
• 4.1 Leaks at shock absorbers
  6
• 4.2 Noises from shock absorbers
  6
• 4.3 Checking shock absorbers when removed
  7
• 4.4 Steering rack
  7
• 4.5 Gaskets and seals
  8
• 4.6 Nuts and bolts
  8
• 4.7 Electrical components
  8
• 4.8 Raising wheel bearing assembly to unladen position
  9
• 5 Disposal
  15
• 5.1 Releasing gas and draining front gas-filled shock absorbers
  15
• 5.2 Releasing gas and draining rear gas-filled shock absorbers
  15
• Front suspension
  17
• 1 Front axle
  17
• 1.1 Overview - front axle
  17
• 2 Subframe
  18
• 2.1 Assembly overview – subframe
  18
• 2.2 Removing and installing anti-roll bar
  18
• 2.3 Renewing anti-roll bar bushes
  20
• 2.4 Removing and installing coupling rod
  21
• 3 Wheel bearing
  23
• 3.1 Assembly overview – wheel bearing assembly
  23
• 3.2 Removing and installing wheel bearing housing
  24
• 3.3 Removing and installing wheel bearing
  27
• 4 Suspension strut, upper suspension link
  34
• 4.1 Assembly overview - suspension strut, upper suspension link
  34
• 4.2 Assembly overview – suspension strut
  36
• 4.3 Removing and installing suspension strut
  36
• 4.4 Removing and installing upper links
  39
• 4.5 Renewing bushes for upper suspension link
  42
• 4.6 Repairing front suspension strut
  44
• 4.7 Removing and installing suspension strut mounting
  48
• 5 Lower suspension link, swivel joint
  50
• 5.1 Removing and installing lower suspension link
  50
• 5.2 Renewing bonded rubber bush for lower suspension link
  52
• 5.3 Checking swivel joint
  56
• 6 Drive shaft
  57
• 6.1 Assembly overview – drive shaft
  57
• 6.2 Removing and installing drive shaft
  59
• 6.3 Dismantling and assembling drive shaft
  63
• 6.4 Checking outer constant velocity joint
  68
• Rear suspension
  70
• 1 Rear axle
  70
• 1.1 Overview – rear axle
  70
• 1.2 Assembly overview - rear axle
  71
• 1.3 Assembly overview - rear axle shafts
  73
• 1.4 Removing and installing leaf spring stop buffer
  75
• 1.5 Removing and installing rear axle
  75
• 1.6 Removing and installing leaf spring
  80
• 1.7 Renewing leaf spring rubber bush
  83
• 1.8 Removing and installing plastic insert for leaf spring
  86
• 1.9 Removing and installing shackle
  87
• 1.10 Aligning leaf spring
  91
• 1.11 Removing and installing rear axle shaft
  92
• 2 Suspension strut, shock absorber, spring
  95
• 2.1 Removing and installing shock absorber
  95
• Wheels, tyres, vehicle geometry
  97
• 1 Wheels, tyres
  97
• 1.1 Specified torques for wheel bolts
  97
• 1.2 Pressing tyre off wheel rim
  97
• 1.3 Removing tyre from wheel
  98
• 1.4 Fitting tyres
  99
• 1.5 Wheel change
  100
• 1.6 Wheel change, wheel installation
  103
• 1.7 Removing and installing spare wheel
  104
• 2 Tyre Pressure Monitoring System
  106
• 2.1 System description - tyre pressure monitoring system with autolocation
  106
• 2.2 Overview of fitting locations - tyre pressure monitoring system
  106
• 2.3 Assembly overview - tyre pressure sensor
  107
• 2.4 Removing and installing tyre pressure monitoring system control unit J502
  108
• 2.5 Removing and installing tyre pressure sensor
  109
• 3 Wheel alignment
  111
• 3.1 Notes for wheel alignment
  111
• 3.2 Necessity of wheel alignment
  111
• 3.3 Conditions for testing
  112
• 3.4 Test preparations
  113
• 3.5 Specifications for wheel alignment
  114
• 3.6 Wheel alignment procedure
  115
• 3.7 Measuring vehicle longitudinal inclination
  116
• 3.8 Adjusting camber and caster at front wheels
  117
• 3.9 Adjusting front axle toe
  118
• 3.10 Vehicle data sticker
  119
• 3.11 Steering angle sender - basic setting
  120
• 4 Vibration due to wheels/tyres - causes and rectification
  121
• 4.1 Causes of rough running
  121
• 4.2 Conducting a road test before balancing wheels
  121
• 4.3 Balancing wheel
  122
• 4.4 Vibration control system
  125
• 4.5 Checking radial and lateral runout of wheels and tyres
  126
• 4.6 Checking radial and lateral run-out on wheel rim
  128
• 4.7 Matching wheels and tyres
  128
• 4.8 Determining flat spots on tyres
  130
• Steering
  132
• 1 Steering wheel
  132
• 1.1 Assembly overview – steering wheel
  132
• 1.2 Removing and installing steering wheel
  132
• 2 Steering column
  135
• 2.1 Assembly overview – steering column
  135
• 2.2 Removing and installing steering column
  136
• 2.3 Handling and transporting steering column
  141
• 2.4 Checking steering column for damage
  142
• 2.5 Removing and installing sealing boot
  142
• 3 Steering rack
  144
• 3.1 Assembly overview – steering rack
  144
• 3.2 Removing and installing steering rack
  144
• 3.3 Repairing steering rack
  148
• 3.4 Checking shock absorber mountings
  149
• 3.5 Removing and installing shock absorber mountings
  150
• 3.6 Removing and installing track rod
  153
• 3.7 Removing and installing track rod ball joint
  157
• 3.8 Removing and installing boot
  159
• 4 Hydraulic power steering
  161
• 4.1 Assembly overview - vane pump
  161
• 4.2 Assembly overview - hydraulic lines, reservoir
  165
• 4.3 Checking delivery pressure of vane pump
  165
• 4.4 Removing and installing vane pump
  168
• 4.5 Checking hydraulic fluid level of power steering
  176
• 4.6 Bleeding steering system
  177
• 4.7 Check steering for leaks
  177