Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 1.2 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 Repair instructions
  4
• 3.1 Leaks at shock absorbers
  4
• 3.2 Noises from shock absorbers
  4
• 3.3 Checking shock absorbers when removed
  5
• 3.4 Steering rack
  5
• 3.5 Gaskets and seals
  6
• 3.6 Nuts and bolts
  6
• 3.7 Electrical components
  6
• 3.8 Raising suspension to unladen position (vehicles with coil springs)
  6
• 4 Waste disposal
  11
• 4.1 Releasing gas and draining front gas-filled shock absorbers
  11
• 4.2 Releasing gas and draining rear gas-filled shock absorbers
  13
• Front suspension
  15
• 1 Front axle
  15
• 1.1 Overview of fitting locations - front axle
  15
• 2 Subframe
  17
• 2.1 Assembly overview – subframe
  17
• 2.2 Assembly overview - subframe strut
  19
• 2.3 Removing and installing subframe without steering rack
  19
• 2.4 Removing and installing subframe with steering rack
  24
• 2.5 Repairing subframe
  37
• 2.6 Removing and installing subframe strut
  45
• 2.7 Removing and installing anti-roll bar
  46
• 2.8 Repairing thread in longitudinal member
  50
• 2.9 Fixing position of subframe
  50
• 2.10 Lowering subframe
  54
• 3 Suspension strut, upper suspension link
  59
• 3.1 Assembly overview - suspension strut, upper suspension link
  59
• 3.2 Removing and installing suspension strut
  60
• 3.3 Repairing suspension strut
  65
• 4 Lower suspension link, swivel joint
  68
• 4.1 Assembly overview - lower suspension link, swivel joint
  68
• 4.2 Removing and installing lower suspension link
  69
• 4.3 Checking swivel joint
  75
• 4.4 Removing and installing swivel joint
  76
• 4.5 Renewing bonded rubber bush for lower suspension link
  79
• 5 Wheel bearing
  84
• 5.1 Assembly overview - wheel bearing
  84
• 5.2 Removing and installing wheel bearing housing
  85
• 5.3 Removing and installing wheel bearing unit
  90
• 6 Drive shaft
  94
• 6.1 Overview - drive shaft
  94
• 6.2 Assembly overview - drive shaft
  95
• 6.3 Removing and installing drive shaft
  101
• 6.4 Loosening and tightening threaded connections of drive shaft
  111
• 6.5 Removing and installing drive shaft heat shield
  113
• 6.6 Dismantling and assembling drive shaft
  113
• 6.7 Checking outer constant velocity joint
  132
• 6.8 Checking inner constant velocity joint
  133
• Rear suspension
  136
• 1 Rear axle
  136
• 1.1 Overview - rear axle
  136
• 1.2 Lowering rear axle
  138
• 1.3 Removing and installing rear axle
  140
• 2 Subframe
  146
• 2.1 Assembly overview – subframe
  146
• 2.2 Assembly overview - radius rod
  148
• 2.3 Fixing position of subframe
  148
• 2.4 Removing and installing radius rods
  150
• 3 Anti-roll bar
  152
• 3.1 Assembly overview - anti-roll bar
  152
• 3.2 Removing and installing anti-roll bar
  152
• 4 Suspension link, track rod
  155
• 4.1 Removing and installing upper transverse link
  155
• 4.2 Removing and installing lower transverse link
  156
• 4.3 Removing and installing track rod
  158
• 5 Suspension strut, shock absorber, spring
  161
• 5.1 Assembly overview - suspension strut, shock absorber, spring
  161
• 5.2 Removing and installing shock absorbers
  161
• 5.3 Repairing shock absorber
  163
• 5.4 Removing and installing spring
  164
• 6 Wheel bearing assembly, trailing arm
  167
• 6.1 Assembly overview - wheel bearing
  167
• 6.2 Removing and installing wheel bearing housing
  168
• 6.3 Removing and installing wheel bearing unit
  171
• 6.4 Removing and installing wheel bearing pre-seal
  174
• 6.5 Renewing bonded rubber bush for wheel bearing housing
  176
• 6.6 Removing and installing trailing arm with mounting bracket
  179
• 6.7 Repairing trailing arm
  183
• Self-levelling suspension
  187
• 1 Vehicle level sender
  187
• 1.1 Assembly overview - rear vehicle level senders
  187
• 1.2 Removing and installing rear vehicle level senders G76 / G77
  187
• Wheels, tyres, vehicle geometry
  189
• 1 Wheels, tyres
  189
• 1.1 Specified torques for wheel bolts
  189
• 1.2 Pressing tyre off wheel rim
  189
• 1.3 Removing tyre from wheel
  190
• 1.4 Fitting tyre
  190
• 1.5 Wheel change
  191
• 1.6 Tyre sealant disposal
  194
• 1.7 Models with breakdown set
  194
• 2 Tyre Pressure Monitoring System
  195
• 2.1 System description - Tyre Pressure Monitoring System
  195
• 3 Wheel alignment
  197
• 3.1 Notes for wheel alignment
  197
• 3.2 Conditions for testing
  197
• 3.3 Test preparations
  198
• 3.4 Specifications for wheel alignment
  199
• 3.5 Wheel alignment procedure
  201
• 3.6 Necessity of wheel alignment
  202
• 3.7 Transverse vehicle inclination - zero position
  203
• 3.8 Adjusting camber at front wheels
  203
• 3.9 Adjusting camber on rear axle
  204
• 3.10 Adjusting toe at rear axle
  205
• 3.11 Adjusting front axle toe
  206
• 3.12 Vehicle data sticker
  207
• 3.13 Steering angle sender G85 basic setting
  208
• 4 Vibration due to wheels/tyres - causes and rectification
  209
• 4.1 Causes of rough running
  209
• 4.2 Conducting a road test before balancing wheels
  209
• 4.3 Balancing wheel
  210
• 4.4 Vibration control system
  214
• 4.5 Checking radial and lateral runout of wheels and tyres
  214
• 4.6 Checking radial and lateral run-out on wheel rim
  215
• 4.7 Matching wheels and tyres
  216
• 4.8 Determining flat spots on tyres
  217
• Steering
  219
• 1 Steering wheel
  219
• 1.1 Assembly overview - steering wheel
  219
• 1.2 Removing and installing steering wheel
  219
• 2 Steering column
  222
• 2.1 Assembly overview - steering column
  222
• 2.2 Checking steering column for damage
  223
• 2.3 Handling and transporting steering column
  224
• 2.4 Removing and installing steering column
  225
• 2.5 Removing and installing control unit for electronic steering column lock J764
  241
• 3 Steering rack
  242
• 3.1 Assembly overview - steering rack
  242
• 3.2 Removing and installing steering rack
  247
• 3.3 Removing and installing boot
  267
• 3.4 Removing and installing track rod
  270
• 3.5 Removing and installing track rod ball joint
  273
• 3.6 Repairing steering rack
  274
• 4 Sensors
  277
• 4.1 Removing and installing steering angle sender G85
  277
• 5 Hydraulic power steering
  279
• 5.1 Assembly overview - hydraulic lines, reservoir
  279
• 5.2 Assembly overview - vane pump
  281
• 5.3 Checking hydraulic fluid level of power steering
  282
• 5.4 Bleeding steering system after repairs
  283
• 5.5 Check steering for leaks
  283
• 5.6 Checking delivery pressure of vane pump
  284
• 5.7 Removing and installing vane pump
  287