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
  13
• 3.4 Repairing thread in longitudinal member
  14
• 3.5 Fixing position of subframe and brackets
  15
• 3.6 Lowering subframe
  16
• 3.7 Removing and installing subframe without steering rack
  20
• 3.8 Removing and installing subframe with steering rack
  24
• 3.9 Repairing subframe
  30
• 3.10 Checking swivel joint
  42
• 3.11 Removing and installing swivel joint
  42
• 3.12 Removing and installing suspension link with mounting bracket
  46
• 3.14 Renewing bonded rubber bush for suspension link
  55
• 3.15 Renewing mounting bracket with suspension link bush
  57
• 3.16 Removing and installing anti-roll bar
  59
• 4 Assembly overview: wheel bearing
  65
• 4.1 Removing and installing wheel bearing housing (3-point mounting)
  67
• 4.2 Removing and installing wheel bearing housing (4-point mounting)
  68
• 4.3 Removing and installing wheel bearing housing
  71
• 5 Assembly overview: suspension strut
  77
• 5.1 Removing and installing suspension strut
  78
• 5.2 Repairing suspension strut
  85
• 6 Removing and installing drive shafts
  88
• 6.1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  88
• 6.3 Removing and installing drive shaft with constant velocity joint
  91
• 6.5 Removing and installing right drive shaft with (push-on) constant velocity slip joint
  99
• 6.6 Removing and installing drive shafts with triple roller joint AAR3300i
  105
• 7 Repairing drive shaft - overview of drive shafts
  110
• 7.1 Heat shields for drive shafts
  111
• 8 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint
  112
• 8.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint
  114
• 8.2 Checking outer constant velocity joint
  118
• 8.3 Checking inner constant velocity joint
  119
• 9 Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on)
  122
• 9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  124
• 10 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on)
  129
• 10.1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint
  130
• 11 Assembly overview: drive shaft with triple roller joint AAR3300i
  134
• 11.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i
  136
• Rear suspension
  142
• 1 Appraisal of accident vehicles
  142
• 2 Repairing rear suspension (front-wheel drive)
  143
• 2.1 Overview - rear axle
  143
• 2.2 Rear axle in unladen position
  144
• 3 Assembly overview: subframe, transverse link, track rod (front-wheel drive)
  147
• 3.1 Fixing position of subframe
  149
• 3.2 Lowering rear axle
  150
• 3.3 Assembly overview: rear left vehicle level sender G76 , front-wheel drive
  153
• 3.4 Removing and installing rear left vehicle level sender G76 (front-wheel drive)
  153
• 3.5 Removing and installing rear axle
  154
• 3.6 Removing and installing upper transverse link
  158
• 3.7 Removing and installing lower transverse link
  160
• 3.8 Removing and installing track rod
  162
• 4 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)
  165
• 4.1 Removing and installing wheel bearing housing
  166
• 4.2 Renewing bonded rubber bush for wheel bearing housing
  169
• 4.3 Removing and installing wheel bearing/wheel hub unit
  172
• 4.4 Removing and installing wheel bearing pre-seal
  175
• 4.5 Removing and installing trailing arm with mounting bracket
  177
• 4.6 Repairing trailing arm
  180
• 5 Assembly overview: shock absorber, coil spring (front-wheel drive)
  184
• 5.1 Removing and installing coil spring
  184
• 5.2 Removing and installing shock absorbers
  186
• 5.3 Repairing shock absorber
  188
• 6 Assembly overview: anti-roll bar (front-wheel drive)
  190
• 6.1 Removing and installing anti-roll bar
  190
• 7 Repairing rear suspension (four-wheel drive)
  193
• 7.1 Overview - rear axle
  193
• 7.2 Rear axle in unladen position
  195
• 8 Assembly overview: subframe, final drive (four-wheel drive)
  198
• 8.1 Fixing position of subframe
  198
• 8.2 Lowering rear axle
  199
• 8.3 Removing and installing rear axle
  202
• 8.4 Repairing subframe, up to Week 21/2012
  206
• 8.5 Repairing subframe, as of Week 22/2012
  212
• 9 Assembly overview: transverse link, track rod (four-wheel drive)
  225
• 9.1 Rear left vehicle level sender G76 (four-wheel drive)
  228
• 9.2 Removing and installing rear left vehicle level sender G76 (four-wheel drive)
  228
• 9.3 Removing and installing upper transverse link
  229
• 9.4 Removing and installing lower transverse link
  231
• 9.5 Removing and installing track rod
  233
• 10 Assembly overview: wheel bearing housing, trailing arm (four-wheel drive)
  236
• 10.1 Removing and installing wheel bearing housing
  238
• 10.2 Renewing bonded rubber bush for wheel bearing housing
  241
• 10.3 Removing and installing wheel bearing/wheel hub unit
  244
• 10.4 Removing and installing trailing arm with mounting bracket
  245
• 10.5 Repairing trailing arm
  248
• 11 Assembly overview: shock absorber, coil spring (four-wheel drive)
  252
• 11.1 Removing and installing coil spring
  252
• 11.2 Removing and installing shock absorbers
  254
• 11.3 Repairing shock absorber
  256
• 12 Assembly overview: anti-roll bar (four-wheel drive)
  258
• 12.1 Removing and installing anti-roll bar
  258
• 13 Assembly overview: drive shaft
  261
• 13.1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  262
• 13.3 Removing and installing drive shaft
  265
• 13.4 Dismantling and assembling drive shaft
  269
• 13.5 Checking outer constant velocity joint
  273
• 13.6 Checking inner constant velocity joint
  274
• Self-levelling suspension
  277
• 1 Appraisal of accident vehicles
  277
• 2 Components of adaptive chassis control DCC and fitting locations
  278
• 2.1 Shock absorber damping adjustment button E387
  279
• 2.2 Removing and installing front left and right body acceleration senders G341/G342
  279
• 2.3 Renewing bracket for front left/right body acceleration sender G341/G342
  280
• 2.5 Removing and installing front left/right vehicle level sender G78/G289
  283
• 2.10 Removing and installing electronically controlled damping control unit J250
  288
• 2.12 Cable routing left front axle
  289
• 2.13 Cable routing right front axle
  291
• 2.14 Cable routing rear axle
  292
• 3 Assembly overview: suspension strut for adaptive chassis control DCC
  293
• 3.1 Removing and installing suspension strut for adaptive chassis control DCC
  295
• 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)
  308
• 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 Specified torques for wheel bolts
  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 Pressing tyre off wheel rim
  327
• 6.3 Removing tyre from wheel
  328
• 6.4 Fitting tyre to wheel rim
  329
• 7 Tyre pressure monitor display
  332
• 7.1 General information
  332
• 7.2 System fault in the ABS system
  333
• 7.3 Perform basic settings
  333
• 8 Tyre pressure monitoring system (TPMS)
  334
• 8.1 Button behaviour
  334
• 8.2 Assembly overview: tyre pressure sensor
  335
• 8.3 Removing and installing tyre pressure sensor
  336
• 9 Vehicle alignment check
  338
• 9.1 General information
  338
• 9.2 Conditions for testing
  340
• 9.3 Test preparations
  340
• 9.4 Wheel alignment specifications
  341
• 9.5 Overview - wheel alignment procedure
  343
• 9.6 Correcting front axle camber
  344
• 9.7 Adjusting camber on rear axle
  346
• 9.8 Adjusting toe at rear axle
  348
• 9.9 Adjusting front axle toe
  348
• 9.10 Basic setting of steering angle sensor G85
  350
• 9.11 Vehicle data sticker
  350
• 10 Wheels, tyres
  351
• 10.1 Models with breakdown set
  351
• 10.2 Tyre sealant
  351
• 10.3 Removing a tyre
  351
• 10.4 Fitting a new tyre
  352
• 10.5 Tyre sealant disposal
  352
• 11 Instructions for changing or fitting wheels
  353
• 11.1 Fitting wheels
  354
• 12 Protecting wheel centring seat against corrosion
  355
• 13 Vibration due to wheels/tyres - causes and rectification
  356
• 13.1 Causes of rough running
  356
• 13.2 Balancing wheels
  356
• 13.3 Conducting a road test before balancing wheels
  356
• 13.4 Balancing wheels on stationary wheel balancing machine
  357
• 13.5 Vibration control system VAS 6230 A
  360
• 13.6 Finish balancer
  360
• 13.7 Radial and lateral runout of wheels and tyres
  361
• 13.9 Checking radial and lateral run-out on wheel rim
  362
• 13.10 Matching
  363
• 13.11 Flat spots caused by storage or handling
  364
• Steering
  366
• 1 Appraisal of accident vehicles
  366
• 2 General repair instructions
  367
• 2.1 Steering rack
  367
• 2.2 Gaskets and seals
  367
• 2.3 Nuts and bolts
  367
• 2.4 Electrical components
  368
• 2.5 Guided fault-finding, vehicle self-diagnosis and test instruments
  368
• 3 Steering wheel, steering column
  369
• 3.1 Removing and installing steering wheel
  369
• 3.2 Assembly overview: steering column, left-hand drive, vehicle with no knee airbag
  372
• 3.4 Assembly overview: steering column, left-hand drive, vehicle with knee airbag . .
  380
• 3.5 Removing and installing steering column, left-hand drive, vehicle with knee airbag
  381
• 3.6 Assembly overview: steering column, right-hand drive
  390
• 3.7 Removing and installing steering column, right-hand drive vehicle
  391
• 3.8 Handling and transporting steering column
  397
• 3.9 Checking steering column for damage
  398
• 4 Electromechanical steering rack
  399
• 4.1 Assembly overview - electromechanical steering rack, left-hand drive
  399
• 4.2 Assembly overview - electromechanical steering rack, right-hand drive
  400
• 4.3 Removing and installing steering rack, left-hand drive vehicle
  401
• 4.4 Removing and installing steering rack, right-hand drive vehicle
  409
• 5 Repairing electromechanical steering rack
  419
• 5.1 Assembly overview: electromechanical steering rack
  419
• 5.2 Removing and installing boot
  420
• 5.3 Removing and installing track rod
  422