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
  11
• 4.2 Fixing position of subframe and brackets
  11
• 4.3 Lowering subframe
  13
• 4.4 Removing and installing subframe without steering rack
  16
• 4.5 Removing and installing subframe with steering rack
  20
• 4.6 Repairing subframe
  25
• 5 Assembly overview: front wheel suspension, suspension link
  38
• 5.1 Checking swivel joint
  39
• 5.2 Removing and installing swivel joint
  40
• 5.3 Removing and installing suspension link with mounting bracket
  43
• 5.5 Renewing bonded rubber bush for suspension link
  52
• 5.6 Renewing mounting bracket with suspension link bush
  54
• 6 Assembly overview: wheel bearing
  57
• 6.1 Removing and installing wheel bearing unit
  58
• 6.2 Removing and installing wheel bearing housing
  60
• 7 Assembly overview: anti-roll bar
  67
• 7.1 Removing and installing anti-roll bar
  67
• 8 Assembly overview: suspension strut
  72
• 8.1 Removing and installing suspension strut
  73
• 8.2 Repairing suspension strut
  79
• 9 Assembly overview - subframe strut
  82
• 9.1 Removing and installing subframe strut
  82
• 10 Removing and installing drive shafts
  84
• 10.1 Loosening and tightening twelve-point bolt for drive shaft connection
  84
• 10.2 Removing and installing drive shaft with constant velocity joint
  85
• 10.3 Removing and installing drive shafts with triple roller joint AAR2600i
  89
• 10.4 Removing and installing drive shafts with triple roller joint AAR3300i
  92
• 11 Repairing drive shafts - overview of drive shafts
  97
• 11.1 Heat shield for drive shafts
  98
• 12 Assembly overview: drive shaft with VL100 constant velocity joint
  99
• 12.1 Dismantling and assembling drive shaft with VL100 constant velocity joint
  101
• 12.2 Checking outer constant velocity joint
  105
• 12.3 Checking inner constant velocity joint
  106
• 13 Assembly overview: drive shaft with VL107 constant velocity joint
  109
• 13.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  111
• 14 Assembly overview: drive shaft with triple roller joint AAR2600i
  116
• 14.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i
  117
• 15 Assembly overview: drive shaft with triple roller joint AAR3300i
  122
• 15.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i
  123
• Rear suspension
  129
• 1 Evaluating accident vehicles
  129
• 2 Rear axle in unladen position
  130
• 3 Overview - rear axle
  132
• 4 Assembly overview: subframe, transverse links track rod
  134
• 4.1 Fixing position of subframe
  136
• 4.2 Lowering rear axle
  137
• 4.3 Assembly overview: rear left vehicle level sender G76
  140
• 4.4 Removing and installing rear left vehicle level sender G76
  141
• 4.5 Removing and installing rear axle
  142
• 4.6 Subframe bracket
  148
• 4.7 Removing and installing upper transverse link
  149
• 4.8 Removing and installing lower transverse link
  151
• 4.9 Removing and installing track rod
  152
• 5 Assembly overview: wheel bearing housing, trailing arm
  155
• 5.1 Removing and installing wheel bearing housing
  156
• 5.2 Renewing bonded rubber bush for wheel bearing housing
  159
• 5.3 Removing and installing wheel bearing unit
  162
• 5.4 Removing and installing wheel bearing pre-seal
  165
• 5.5 Removing and installing trailing arm with mounting bracket
  167
• 5.6 Repairing trailing arm
  171
• 6 Assembly overview: shock absorber, coil spring
  175
• 6.1 Removing and installing coil spring
  175
• 6.2 Removing and installing shock absorbers
  177
• 6.3 Repairing shock absorber
  179
• 7 Assembly overview: anti-roll bar
  181
• 7.1 Removing and installing anti-roll bar
  181
• 8 Assembly overview - tie bars
  184
• 8.1 Removing and installing radius rods
  184
• Self-levelling suspension
  186
• 1 Appraisal of accident vehicles
  186
• 2 Components of adaptive chassis control DCC and fitting locations
  187
• 2.1 Shock absorber damping adjustment button E387
  188
• 2.2 Removing and installing front left and right body acceleration senders G341/G342
  188
• 2.3 Renewing bracket for front left/right body acceleration sender G341/G342
  189
• 2.5 Removing and installing front left/right vehicle level sender G78/G289
  192
• 2.6 Assembly overview: rear left vehicle level sender G76 for adaptive chassis control DCC
  193
• 2.8 Removing and installing electronically controlled damping control unit J250
  195
• 2.9 Basic setting of adaptive chassis control DCC
  196
• 2.10 Cable routing left front axle
  197
• 2.11 Cable routing right front axle
  198
• 2.12 Cable routing rear axle
  199
• 3 Assembly overview: suspension strut for adaptive chassis control DCC
  200
• 3.1 Removing and installing suspension strut for adaptive chassis control DCC
  201
• 4 Assembly overview: shock absorber for adaptive chassis control DCC
  209
• 4.1 Removing and installing rear body acceleration sender G343
  210
• 4.2 Removing and installing shock absorber for adaptive chassis control DCC
  211
• 4.3 Repairing shock absorber for adaptive chassis control DCC
  213
• Wheels, tyres, vehicle geometry
  216
• 1 Evaluating accident vehicles
  216
• 2 Specified torques for wheel bolts
  217
• 3 Position of anti-theft wheel bolts for steel wheels
  218
• 4 Fitting wheel and tyre
  219
• 4.1 General information
  219
• 4.2 Fittings instructions
  219
• 5 Tyre pressure monitor display
  221
• 5.1 General information
  221
• 5.2 System fault in the ABS system
  222
• 5.3 Perform basic settings
  222
• 6 Vehicle alignment check
  223
• 6.1 General information
  223
• 6.2 Prerequisites for testing
  225
• 6.3 Test preparations
  225
• 6.4 Wheel alignment specifications
  226
• 6.5 Overview - wheel alignment procedure
  227
• 6.6 Correcting front axle camber
  228
• 6.7 Adjusting camber on rear axle
  229
• 6.8 Adjusting toe at rear axle
  231
• 6.9 Adjusting front axle toe
  232
• 6.10 Basic setting of steering angle sensor G85
  233
• 6.11 Vehicle data sticker
  233
• 7 Wheels, tyres
  234
• 7.1 Models with breakdown set
  234
• 7.2 Tyre sealant
  234
• 7.3 Removing a tyre
  234
• 7.4 Fitting a new tyre
  235
• 7.5 Tyre sealant disposal
  235
• 8 Instructions for changing or fitting wheels
  236
• 8.1 Fitting wheels
  237
• 9 Protecting wheel centring seat against corrosion
  238
• 10 Vibration due to wheels/tyres - causes and rectification
  239
• 10.1 Causes of rough running
  239
• 10.2 Balancing wheels
  239
• 10.3 Conducting a road test before balancing wheels
  239
• 10.4 Balancing wheels on stationary wheel balancing machine
  240
• 10.5 Vibration control system VAS 6230 A
  243
• 10.6 Finish balancer
  243
• 10.7 Radial and lateral runout of wheels and tyres
  244
• 10.9 Checking radial and lateral run-out on wheel rim
  245
• 10.10 Matching
  246
• 10.11 Flat spots caused by storage or handling
  247
• Steering
  249
• 1 Evaluating accident vehicles
  249
• 2 General repair instructions
  250
• 2.1 Steering rack
  250
• 2.2 Gaskets and seals
  250
• 2.3 Nuts and bolts
  250
• 2.4 Electrical components
  251
• 2.5 Guided Fault Finding, vehicle self-diagnosis and Test Instruments
  251
• 3 Assembly overview - airbag and steering wheel
  252
• 3.1 Removing and installing airbag and steering wheel
  252
• 4.2 Handling and transporting steering column
  264
• 4.3 Checking steering column for damage
  265
• 5.1 Removing and installing steering column, left-hand drive, vehicle with knee airbag
  266
• 5.2 Handling and transporting steering column
  275
• 5.3 Checking steering column for damage
  276
• 6 Electromechanical steering rack, LHD vehicle
  277
• 6.1 Assembly overview - electromechanical steering rack, left-hand drive
  277
• 6.2 Removing and installing steering rack, left-hand drive vehicle
  278
• 7 Repairing electromechanical power steering rack
  286
• 7.1 Assembly overview: electromechanical steering rack
  286
• 7.2 Removing and installing track rod
  287
• 7.3 Removing and installing track rod ball joint
  290
• 7.4 Removing and installing boot
  291
• 7.5 Checking play, security and boots of track rod ends
  294
• 7.6 Checking and adjusting track rod length
  294
• 7.7 Allocation of track rod ball joints
  295