Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Evaluating accident vehicles
  1
• 1.1 Check list for evaluating running gear on accident vehicles
  1
• 2 General information
  3
• 2.1 Tyre types
  3
• 3 Repair instructions
  4
• 3.1 Steering rack
  4
• 3.2 Gaskets and seals
  4
• 3.3 Nuts and bolts
  5
• 3.4 Electrical components
  5
• 3.5 Raising suspension to unladen position (vehicles with coil springs)
  5
• Front suspension
  10
• 1 Front axle
  10
• 1.1 Overview of fitting locations - front axle
  10
• 2 Subframe
  12
• 2.1 Assembly overview – subframe
  12
• 2.2 Assembly overview - subframe strut
  15
• 2.3 Removing and installing subframe strut
  15
• 2.4 Fixing position of subframe
  16
• 2.5 Lowering subframe
  20
• 2.6 Removing and installing subframe without steering rack
  23
• 2.7 Removing and installing subframe with steering rack
  28
• 2.8 Repairing subframe
  41
• 2.9 Removing and installing anti-roll bar
  49
• 2.10 Repairing thread in longitudinal member
  53
• 3 Suspension strut, upper suspension link
  54
• 3.1 Assembly overview - suspension strut, upper suspension link
  54
• 3.2 Removing and installing suspension strut
  55
• 3.3 Repairing suspension strut
  60
• 4 Lower suspension link, swivel joint
  63
• 4.1 Assembly overview - lower suspension link, swivel joint
  63
• 4.2 Removing and installing lower suspension link
  65
• 4.3 Checking swivel joint
  71
• 4.4 Removing and installing swivel joint
  72
• 4.5 Renewing bonded rubber bush for lower suspension link
  75
• 5 Wheel bearing
  80
• 5.1 Assembly overview - wheel bearing
  80
• 5.2 Removing and installing wheel bearing housing
  81
• 5.3 Removing and installing wheel bearing unit
  86
• 6 Drive shaft
  90
• 6.1 Overview - drive shaft
  90
• 6.2 Assembly overview - drive shaft
  91
• 6.3 Removing and installing drive shaft
  97
• 6.4 Loosening and tightening threaded connections of drive shaft
  107
• 6.5 Removing and installing drive shaft heat shield
  109
• 6.6 Dismantling and assembling drive shaft
  109
• 6.7 Checking outer constant velocity joint
  128
• 6.8 Checking inner constant velocity joint
  129
• Rear suspension
  132
• 1 Rear axle
  132
• 1.1 Overview - rear axle
  132
• 1.2 Lowering rear axle
  137
• 1.3 Removing and installing rear axle
  139
• 2 Axle beam
  148
• 2.1 Assembly overview – axle beam
  148
• 2.2 Assembly overview - plate for axle beam
  150
• 2.3 Removing and installing axle assembly
  151
• 2.4 Removing and installing plate for axle beam
  156
• 2.5 Renewing bonded rubber bush for axle beam
  162
• 2.6 Removing and installing cross piece
  167
• 2.7 Renewing bonded rubber bush for cross strut
  170
• 3 Subframe
  173
• 3.1 Assembly overview – subframe
  173
• 3.2 Assembly overview - radius rod
  175
• 3.3 Fixing position of subframe
  175
• 3.4 Removing and installing radius rods
  177
• 4 Anti-roll bar
  179
• 4.1 Assembly overview - anti-roll bar
  179
• 4.2 Removing and installing anti-roll bar
  179
• 5 Suspension link, track rod
  182
• 5.1 Removing and installing upper transverse link
  182
• 5.2 Removing and installing lower transverse link
  183
• 5.3 Removing and installing track rod
  185
• 6 Suspension strut, shock absorber, spring
  188
• 6.1 Assembly overview - suspension strut, shock absorber, spring
  188
• 6.2 Removing and installing shock absorbers
  190
• 6.3 Repairing shock absorber
  193
• 6.4 Removing and installing spring
  195
• 7 Wheel bearing assembly, trailing arm
  200
• 7.1 Assembly overview - wheel bearing
  200
• 7.2 Removing and installing wheel bearing housing
  204
• 7.3 Removing and installing wheel bearing unit
  207
• 7.4 Removing and installing wheel bearing pre-seal
  216
• 7.5 Renewing bonded rubber bush for wheel bearing housing
  218
• 7.6 Removing and installing trailing arm with mounting bracket
  221
• 7.7 Repairing trailing arm
  225
• Self-levelling suspension
  229
• 1 Vehicle level sender
  229
• 1.1 Assembly overview - rear vehicle level senders
  229
• 1.2 Removing and installing rear vehicle level senders G76 / G77
  230
• Wheels, tyres, vehicle geometry
  233
• 1 Wheels, tyres
  233
• 1.1 Specified torques for wheel bolts
  233
• 1.2 Pressing tyre off wheel rim
  233
• 1.3 Removing tyre from wheel
  234
• 1.4 Fitting tyre
  234
• 1.5 Wheel change
  235
• 1.6 Tyre sealant disposal
  238
• 1.7 Models with breakdown set
  238
• 2 Tyre Pressure Monitoring System
  239
• 2.1 System description - Tyre Pressure Monitoring System
  239
• 3 Wheel alignment
  241
• 3.1 Notes for wheel alignment
  241
• 3.2 Conditions for testing
  242
• 3.3 Test preparations
  242
• 3.4 Checking trailing arm of axle beam (torsion beam rear axle) using VAS 241 001
  244
• 3.5 Checking trailing arm of axle beam (torsion beam rear axle) using VAS 801
  246
• 3.6 Specifications for wheel alignment
  249
• 3.7 Wheel alignment procedure
  251
• 3.8 Necessity of wheel alignment
  252
• 3.9 Transverse vehicle inclination - zero position
  255
• 3.10 Adjusting camber at front wheels
  255
• 3.11 Adjusting camber on rear axle
  257
• 3.12 Adjusting toe at rear axle
  258
• 3.13 Adjusting front axle toe
  259
• 3.14 Vehicle data sticker
  260
• 3.15 Steering angle sender G85 basic setting
  260
• 4 Vibration due to wheels/tyres - causes and rectification
  261
• 4.1 Causes of rough running
  261
• 4.2 Conducting a road test before balancing wheels
  261
• 4.3 Balancing wheel
  262
• 4.4 Vibration control system
  266
• 4.5 Checking radial and lateral runout of wheels and tyres
  266
• 4.6 Checking radial and lateral run-out on wheel rim
  267
• 4.7 Matching wheels and tyres
  268
• 4.8 Determining flat spots on tyres
  269
• Steering
  271
• 1 Steering wheel
  271
• 1.1 Assembly overview - steering wheel
  271
• 1.2 Removing and installing steering wheel
  271
• 2 Steering column
  274
• 2.1 Assembly overview - steering column
  274
• 2.2 Checking steering column for damage
  276
• 2.3 Handling and transporting steering column
  277
• 2.4 Removing and installing steering column
  278
• 2.5 Removing and installing control unit for electronic steering column lock J764
  294
• 3 Steering rack
  296
• 3.1 Assembly overview - steering rack
  296
• 3.2 Removing and installing steering rack
  301
• 3.3 Removing and installing boot
  321
• 3.4 Removing and installing track rod
  324
• 3.5 Removing and installing track rod ball joint
  327
• 3.6 Repairing steering rack
  328
• 4 Hydraulic power steering
  331
• 4.1 Assembly overview - hydraulic lines, reservoir
  331
• 4.2 Assembly overview - vane pump
  333
• 4.3 Checking hydraulic fluid level of power steering
  334
• 4.4 Bleeding steering system after repairs
  335
• 4.5 Check steering for leaks
  335
• 4.6 Checking delivery pressure of vane pump
  336
• 4.7 Removing and installing vane pump
  339
• 5 Sensors
  342
• 5.1 Removing and installing steering angle sender G85
  342