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
  8
• 3.1 Assembly overview: subframe, anti-roll bar, suspension links
  8
• 3.2 Repairing thread in longitudinal member
  11
• 3.3 Fixing position of subframe
  11
• 3.4 Lowering subframe
  13
• 3.5 Removing and installing subframe without steering rack
  17
• 3.6 Removing and installing subframe with steering rack
  21
• 3.7 Repairing subframe
  26
• 3.8 Checking swivel joint
  38
• 3.9 Removing and installing swivel joint
  38
• 3.10 Removing and installing suspension link with mounting bracket
  42
• 3.12 Renewing bonded rubber bush for suspension link
  50
• 3.13 Renewing mounting bracket with suspension link bush
  52
• 3.14 Removing and installing anti-roll bar
  54
• 4 Assembly overview - wheel bearings
  60
• 4.1 Removing and installing wheel bearing unit
  62
• 4.2 Removing and installing wheel bearing housing
  64
• 5 Assembly overview: suspension strut
  69
• 5.1 Removing and installing suspension strut
  70
• 5.2 Repairing suspension strut
  76
• 6 Removing and installing drive shafts
  79
• 6.1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  79
• 6.3 Removing and installing drive shaft with constant velocity joint
  82
• 6.5 Removing and installing right drive shaft with (push-on) constant velocity slip joint
  90
• 6.7 Removing and installing drive shafts with triple roller joint AAR3300i (pushed into gearbox)
  102
• 7 Repairing drive shaft - overview of drive shafts
  107
• 7.1 Heat shields for drive shafts
  108
• 8 Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on)
  109
• 8.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  111
• 8.2 Checking outer constant velocity joint
  115
• 8.3 Checking inner constant velocity joint
  116
• 9 Assembly overview: drive shaft with VL107 constant velocity slip joint
  118
• 9.2 Checking outer constant velocity joint
  124
• 10 Assembly overview: drive shaft with triple roller joint AAR3300i
  126
• 10.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i
  128
• Rear suspension
  140
• 1 Appraisal of accident vehicles
  140
• 2 Repairing rear suspension (front-wheel drive)
  141
• 2.1 Overview - rear axle
  141
• 2.2 Rear axle in unladen position
  143
• 3 Assembly overview: subframe up to model year 2010 (front-wheel drive)
  145
• 3.1 Removing and installing rear axle
  145
• 3.2 Repairing subframe
  149
• 4 Assembly overview: transverse link, track rod up to model year 2010 (front-wheel drive)
  154
• 4.1 Assembly overview: rear left vehicle level sender G76 , front-wheel drive
  157
• 4.2 Removing and installing rear left vehicle level sender G76
  157
• 4.3 Removing and installing upper transverse link
  158
• 4.4 Removing and installing lower transverse link
  160
• 4.5 Removing and installing track rod
  162
• 5 Allocation of track rods to trailing arms (front- and four-wheel drive)
  165
• 6.1 Assembly overview: rear left vehicle level sender G76 (front-wheel drive)
  169
• 6.2 Removing and installing rear left vehicle level sender G76
  169
• 6.3 Removing and installing rear axle
  170
• 6.4 Removing and installing upper transverse link
  173
• 6.5 Removing and installing lower transverse link
  175
• 6.6 Removing and installing track rod
  177
• 7 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)
  180
• 7.1 Removing and installing wheel bearing housing
  181
• 7.2 Renewing bonded rubber bush for wheel bearing housing
  185
• 7.3 Removing and installing wheel bearing/wheel hub unit
  187
• 7.4 Removing and installing trailing arm with mounting bracket
  190
• 7.5 Repairing trailing arm
  194
• 8 Assembly overview: shock absorber, coil spring (front-wheel drive)
  197
• 8.1 Removing and installing coil spring
  197
• 8.2 Removing and installing shock absorbers
  199
• 8.3 Repairing shock absorber
  201
• 9 Assembly overview: anti-roll bar (front-wheel drive)
  203
• 9.1 Removing and installing anti-roll bar
  203
• 10 Repairing rear suspension (four-wheel drive)
  206
• 10.1 Overview - rear axle
  206
• 10.2 Rear axle in unladen position
  208
• 11 Assembly overview: subframe, final drive (four-wheel drive)
  210
• 11.1 Removing and installing rear axle
  210
• 11.2 Repairing subframe, up to Week 21/2012
  215
• 11.3 Repairing subframe, as of Week 22/2012
  223
• 12 Assembly overview: transverse link, track rod (four-wheel drive)
  237
• 12.1 Overview - rear left vehicle level sender G76
  240
• 12.2 Removing and installing rear left vehicle level sender G76
  240
• 12.3 Removing and installing upper transverse link
  241
• 12.4 Removing and installing lower transverse link
  243
• 12.5 Removing and installing track rod
  245
• 13 Assembly overview: wheel bearing housing, trailing arm (four-wheel drive)
  249
• 13.1 Removing and installing wheel bearing housing
  251
• 13.2 Renewing bonded rubber bush for wheel bearing housing
  254
• 13.3 Removing and installing wheel bearing/wheel hub unit
  257
• 13.4 Removing and installing trailing arm with mounting bracket
  258
• 13.5 Repairing trailing arm
  261
• 14 Assembly overview: shock absorber, coil spring (four-wheel drive)
  264
• 14.1 Removing and installing coil spring
  264
• 14.2 Removing and installing shock absorbers
  266
• 14.3 Repairing shock absorber
  268
• 15 Assembly overview: anti-roll bar (four-wheel drive)
  270
• 15.1 Removing and installing anti-roll bar
  270
• 16 Assembly overview: drive shaft
  273
• 16.1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  274
• 16.3 Removing and installing drive shaft
  277
• 16.4 Dismantling and assembling drive shaft
  281
• 16.5 Checking inner constant velocity joint
  285
• Self-levelling suspension
  287
• 1 Appraisal of accident vehicles
  287
• 2 Components of adaptive chassis control DCC and fitting locations
  288
• 2.1 Shock absorber damping adjustment button E387
  289
• 2.2 Removing and installing front left body acceleration sender G341
  289
• 2.3 Removing and installing front right body acceleration sender G342
  290
• 2.4 Renewing bracket for front left/right body acceleration sender G341/G342
  291
• 2.6 Removing and installing front left/right vehicle level sender G78/G289
  294
• 2.11 Removing and installing electronically controlled damping control unit J250
  299
• 2.12 Basic setting of adaptive chassis control DCC
  299
• 2.13 Cable routing left front axle
  300
• 2.14 Cable routing right front axle
  301
• 2.15 Cable routing rear axle
  302
• 3 Assembly overview: suspension strut for adaptive chassis control DCC
  303
• 3.1 Removing and installing suspension strut for adaptive chassis control DCC
  305
• 4 Assembly overview: shock absorber for adaptive chassis control DCC (front-wheel drive)
  313
• 4.1 Removing and installing rear body acceleration sender G343 (front-wheel drive)
  314
• 4.3 Repairing shock absorber for adaptive chassis control DCC (front-wheel drive)
  317
• 5 Assembly overview: shock absorber for adaptive chassis control DCC (four-wheel drive)
  320
• 5.1 Removing and installing rear body acceleration sender G343 (four-wheel drive)
  321
• Wheels, tyres, vehicle geometry
  327
• 1 Appraisal of accident vehicles
  327
• 2 Torque settings for wheels
  328
• 3 Vehicle alignment check
  329
• 3.1 General information
  329
• 3.2 Conditions for testing
  331
• 3.3 Test preparations
  331
• 3.4 Wheel alignment specifications
  332
• 3.5 Overview - wheel alignment procedure
  333
• 3.6 Correcting front axle camber
  334
• 3.7 Adjusting camber on rear axle
  336
• 3.8 Adjusting toe at rear axle
  337
• 3.9 Adjusting front axle toe
  338
• 3.10 Basic setting of steering angle sensor G85
  339
• 3.11 Vehicle data sticker
  339
• 4 Front camera for driver assist systems R242
  340
• 4.1 Adjusting front camera for driver assistance system R242
  340
• Steering
  348
• 1 Appraisal of accident vehicles
  348
• 2 General repair instructions
  349
• 2.1 Steering rack
  349
• 2.2 Gaskets and seals
  349
• 2.3 Nuts and bolts
  349
• 2.4 Electrical components
  350
• 2.5 Guided Fault Finding, vehicle self-diagnosis and Test Instruments
  350
• 3 Steering column and steering wheel
  351
• 3.1 Assembly overview: steering column, left-hand drive
  351
• 3.2 Assembly overview: steering column, right-hand drive
  352
• 3.3 Removing and installing steering wheel
  352
• 3.4 Removing and installing steering column
  355
• 3.6 Handling and transporting steering column
  360
• 3.7 Checking steering column for damage
  362
• 3.8 Removing and installing mounting bracket, RHD
  362
• 4 Electromechanical steering rack
  364
• 4.1 Assembly overview - electromechanical steering rack, left-hand drive
  364
• 4.4 Removing and installing steering rack, left-hand drive vehicle
  369
• 4.5 Removing and installing steering rack, right-hand drive vehicle
  378
• 5 Differentiating between 2nd and 3rd generation steering racks
  388
• 6 Repairing electromechanical steering rack, left-hand drive vehicles
  389
• 6.1 Assembly overview: electromechanical steering rack, LHD vehicle
  389
• 6.2 Renewing bonded rubber bushes for power-assisted steering rack
  390
• 6.3 Removing and installing boot
  392
• 6.4 Checking play, security and boots of track rod ends
  394
• 6.5 Removing and installing track rod
  394
• 7 Repairing electromechanical steering rack, right-hand drive vehicles
  398
• 7.1 Assembly overview: electromechanical steering rack, RHD vehicle
  398
• 7.2 Removing and installing boot
  399
• 7.3 Checking play, security and boots of track rod ends
  401
• 7.4 Removing and installing track rod
  401