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
  14
• 3.4 Repairing thread in longitudinal member
  15
• 3.5 Fixing position of subframe
  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
  25
• 3.9 Repairing subframe
  30
• 3.10 Checking swivel joint
  38
• 3.11 Removing and installing swivel joint
  39
• 3.12 Removing and installing suspension link with mounting bracket
  42
• 3.14 Renewing bonded rubber bush for suspension link
  50
• 3.15 Renewing mounting bracket with suspension link bush
  52
• 3.16 Removing and installing anti-roll bar
  54
• 4 Assembly overview: wheel bearing
  60
• 4.1 Removing and installing wheel bearing unit
  62
• 4.2 Removing and installing wheel bearing housing
  63
• 5 Assembly overview: suspension strut
  69
• 5.1 Removing and installing suspension strut
  71
• 5.2 Repairing suspension strut
  77
• 6 Removing and installing drive shafts
  80
• 6.1 Loosening and tightening drive shaft hexagon bolt
  80
• 6.2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  81
• 6.4 Removing and installing drive shaft with constant velocity joint
  84
• 6.6 Removing and installing drive shafts with triple roller joint AAR3300i (bolted on)
  92
• 7 Repairing drive shaft - overview of drive shafts
  97
• 7.1 Heat shields for drive shafts
  98
• 8 Assembly overview: drive shaft with VL100 constant velocity joint
  99
• 8.1 Dismantling and assembling drive shaft with VL100 constant velocity joint
  101
• 8.2 Checking outer constant velocity joint
  105
• 8.3 Checking inner constant velocity joint
  106
• 9 Assembly overview: drive shaft with VL107 constant velocity joint
  109
• 9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  111
• 10 Assembly overview: drive shaft with triple roller joint AAR2600i
  116
• 10.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i
  118
• 11 Assembly overview: drive shaft with triple roller joint AAR3300i
  123
• 11.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i
  125
• Rear suspension
  137
• 1 Appraisal of accident vehicles
  137
• 2 Repairing rear suspension (front-wheel drive)
  138
• 2.1 Overview - rear axle
  138
• 2.2 Rear axle in unladen position
  140
• 3 Assembly overview: subframe (front-wheel drive)
  143
• 3.1 Removing and installing rear axle
  143
• 3.2 Repairing subframe
  147
• 4 Assembly overview: transverse link, track rod (front-wheel drive)
  152
• 4.3 Removing and installing rear left vehicle level sender G76 up to model year 2007
  156
• 4.5 Removing and installing upper transverse link
  158
• 4.6 Removing and installing lower transverse link
  160
• 4.7 Removing and installing track rod
  162
• 5 Allocation of track rods to trailing arms (front- and four-wheel drive)
  166
• 6 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)
  168
• 6.1 Removing and installing wheel bearing housing
  169
• 6.2 Renewing bonded rubber bush for wheel bearing housing
  173
• 6.3 Removing and installing wheel bearing/wheel hub unit
  176
• 6.4 Removing and installing trailing arm with mounting bracket
  180
• 6.5 Repairing trailing arm
  183
• 7 Assembly overview: shock absorber, coil spring (front-wheel drive)
  186
• 7.1 Converting to Nivomat
  187
• 7.2 Converting to heavy-duty running gear
  187
• 7.3 Removing and installing coil spring
  187
• 7.4 Removing and installing shock absorbers
  188
• 7.5 Repairing shock absorber
  190
• 8 Assembly overview: anti-roll bar (front-wheel drive)
  193
• 8.1 Removing and installing anti-roll bar
  193
• 9 Repairing rear suspension (four-wheel drive)
  196
• 9.1 Overview - rear axle
  196
• 9.2 Rear axle in unladen position
  198
• 10 Assembly overview: subframe, final drive (four-wheel drive)
  201
• 10.1 Preparatory work for when installing a steel subframe
  202
• 10.2 Removing and installing rear axle
  203
• 10.3 Repairing aluminium subframe
  208
• 10.4 Repairing steel subframe
  212
• 11 Assembly overview: transverse link, track rod (four-wheel drive)
  220
• 11.1 Rear left vehicle level sender G76 , four-wheel drive up to model year 2007
  223
• 11.2 Rear left vehicle level sender G76 , four-wheel drive from model year 2008
  224
• 11.5 Removing and installing upper transverse link
  226
• 11.6 Removing and installing lower transverse link
  228
• 11.7 Removing and installing track rod
  230
• 12 Assembly overview: wheel bearing housing, trailing arm (four-wheel drive)
  233
• 12.1 Removing and installing wheel bearing housing
  235
• 12.2 Renewing bonded rubber bush for wheel bearing housing
  238
• 12.3 Removing and installing wheel bearing/wheel hub unit
  241
• 12.4 Removing and installing trailing arm with mounting bracket
  242
• 12.5 Repairing trailing arm
  246
• 13 Assembly overview: shock absorber, coil spring (four-wheel drive)
  250
• 13.1 Converting to Nivomat
  251
• 13.2 Converting to heavy-duty running gear
  251
• 13.3 Removing and installing coil spring
  251
• 13.4 Removing and installing shock absorbers
  252
• 13.5 Repairing shock absorber
  254
• 14 Assembly overview: anti-roll bar (four-wheel drive)
  257
• 14.1 Removing and installing anti-roll bar
  257
• 15 Assembly overview: drive shaft
  261
• 15.1 Loosening and tightening drive shaft hexagon bolt
  263
• 15.2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  264
• 15.4 Removing and installing drive shaft
  267
• 15.5 Dismantling and assembling drive shaft
  270
• 15.6 Checking outer constant velocity joint
  275
• 15.7 Checking inner constant velocity joint
  276
• Self-levelling suspension
  278
• 1 Appraisal of accident vehicles
  278
• 2 Components of adaptive chassis control DCC and fitting locations
  279
• 2.1 Shock absorber damping adjustment button E387
  280
• 2.2 Removing and installing front left body acceleration sender G341
  280
• 2.3 Removing and installing front right body acceleration sender G342
  281
• 2.4 Renewing bracket for front left/right body acceleration sender G341/G342
  282
• 2.6 Removing and installing front left/right vehicle level sender G78/G289
  285
• 2.11 Removing and installing electronically controlled damping control unit J250
  290
• 2.12 Basic setting of adaptive chassis control DCC
  290
• 2.13 Cable routing left front axle
  291
• 2.14 Cable routing right front axle
  292
• 2.15 Cable routing rear axle
  293
• 3 Assembly overview: suspension strut for adaptive chassis control DCC
  294
• 3.1 Removing and installing suspension strut for adaptive chassis control DCC
  296
• 4 Assembly overview: shock absorber for adaptive chassis control DCC (front-wheel drive)
  304
• 4.1 Removing and installing rear body acceleration sender G343 (front-wheel drive)
  305
• 4.3 Repairing shock absorber for adaptive chassis control DCC (front-wheel drive)
  309
• 5 Assembly overview: shock absorber for adaptive chassis control DCC (four-wheel drive)
  311
• 5.1 Removing and installing rear body acceleration sender G343 (four-wheel drive)
  312
• Wheels, tyres, vehicle geometry
  318
• 1 Appraisal of accident vehicles
  318
• 2 Torque settings for wheels
  319
• 3 Position of anti-theft wheel bolts for steel wheels
  320
• 4 Fitting wheel and tyre
  321
• 4.1 General information
  321
• 4.2 Fittings instructions
  321
• 5 Removing and fitting tyres (wheels with tyre pressure monitoring)
  323
• 5.2 Wheel change
  323
• 5.3 Pressing tyre off wheel rim
  324
• 5.4 Removing tyre from wheel
  325
• 5.5 Fitting tyre to wheel rim
  325
• 6 Removing and fitting tyres with run-flat properties to wheel rims
  327
• 6.1 Safety information
  327
• 6.2 Fittings instructions
  327
• 6.3 Pressing tyre off wheel rim
  328
• 6.4 Removing tyre from wheel
  329
• 6.5 Fitting tyre to wheel rim
  330
• 7 Self-sealing tyres “ContiSeal”
  333
• 7.1 Explanation for mobility tyres
  333
• 7.2 Handling mobility tyres
  334
• 8 Tyre pressure monitor display
  335
• 9 Tyre pressure monitoring system (TPMS)
  337
• 9.1 Button behaviour
  337
• 9.2 Assembly overview: tyre pressure sensor
  338
• 9.3 Removing and installing tyre pressure sensor
  339
• 10 Vehicle alignment check
  341
• 10.1 General information
  341
• 10.2 Conditions for testing
  343
• 10.3 Test preparations
  343
• 10.4 Wheel alignment specifications
  344
• 10.5 Overview - wheel alignment procedure
  347
• 10.6 Correcting front axle camber
  348
• 10.7 Adjusting camber on rear axle
  349
• 10.8 Adjusting toe at rear axle
  351
• 10.9 Adjusting front axle toe
  351
• 10.10 Basic setting of steering angle sensor G85
  352
• 10.11 Vehicle data sticker
  352
• 11 Adaptive Cruise Control (ACC)
  354
• 11.1 General information on ACC calibration
  354
• 11.2 ACC calibration during vehicle alignment
  354
• 11.3 ACC calibration without prior vehicle alignment
  356
• 12 Lane departure warning
  359
• 12.1 General information about lane departure warning
  359
• 12.2 Calibrating the lane departure warning
  360
• 13 Wheels, tyres
  367
• 13.1 Models with breakdown set
  367
• 13.2 Tyre sealant
  367
• 13.3 Removing a tyre
  367
• 13.4 Fitting a new tyre
  368
• 13.5 Tyre sealant disposal
  368
• 14 Instructions for changing or fitting wheels
  369
• 14.1 Fitting wheels
  370
• 15 Protecting wheel centring seat against corrosion
  371
• 16 Vibration due to wheels/tyres - causes and rectification
  372
• 16.1 Causes of rough running
  372
• 16.2 Balancing wheels
  372
• 16.3 Conducting a road test before balancing wheels
  372
• 16.4 Balancing wheels on stationary wheel balancing machine
  373
• 16.5 Vibration control system VAS 6230 A
  376
• 16.6 Finish balancer
  376
• 16.7 Radial and lateral runout of wheels and tyres
  377
• 16.9 Checking radial and lateral run-out on wheel rim
  378
• 16.10 Matching
  379
• 16.11 Flat spots caused by storage or handling
  380
• Steering
  382
• 1 Appraisal of accident vehicles
  382
• 2 General repair instructions
  383
• 2.1 Steering rack
  383
• 2.2 Gaskets and seals
  383
• 2.3 Nuts and bolts
  383
• 2.4 Electrical components
  384
• 2.5 Guided Fault Finding, vehicle self-diagnosis and test instruments
  384
• 3 Assembly overview: steering column
  385
• 3.1 Removing and installing steering wheel
  386
• 3.2 Removing and installing steering column
  388
• 3.4 Handling and transporting steering column
  393
• 3.5 Checking steering column for damage
  394
• 3.6 Removing and installing electronic steering column lock control unit J764
  394
• 3.7 Removing and installing mounting bracket
  396
• 3.8 Removing and installing strut
  398
• 4 Electromechanical steering rack up to model year 2008
  400
• 5 Electromechanical steering rack from model year 2009
  422
• 5.3 Removing and installing steering rack, left-hand drive vehicle (APA) from model year 2009
  425
• 6 Differentiating between 2nd and 3rd generation steering racks
  442
• 7.1 Removing and installing bellows
  443
• 7.2 Removing and installing track rod
  445
• 8.1 Assembly overview: electromechanical steering rack, left-hand drive vehicle
  449
• 8.2 Renewing bonded rubber bushes for power-assisted steering rack
  450
• 8.3 Removing and installing track rod
  452
• 8.4 Removing and installing track rod ball joint
  456
• 8.5 Removing and installing bellows
  457
• 8.6 Checking play, security and boots of track rod ends
  460
• 8.7 Allocation of track rod ball joints
  460
• 9 Repairing electromechanical steering rack, right-hand drive vehicles
  461
• 9.1 Assembly overview: electromechanical steering rack, RHD vehicle
  461
• 9.2 Removing and installing track rod
  462
• 9.3 Removing and installing track rod ball joint
  465
• 9.4 Removing and installing bellows
  466
• 9.5 Checking play, security and boots of track rod ends
  469
• 9.6 Allocation of track rod ball joints
  469