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 Repairing front wheel 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 Repairing thread in longitudinal member
  11
• 3.3 Fixing position of subframe (all vehicles except for R WRC)
  11
• 3.4 Fixing position of subframe (R WRC)
  14
• 3.5 Removing and installing subframe
  16
• 3.6 Checking swivel joint
  18
• 3.7 Removing and installing swivel joint
  18
• 3.8 Installation position of swivel joints
  21
• 3.9 Removing and installing suspension link
  22
• 3.10 Renewing front bonded rubber bush for suspension link
  27
• 3.11 Renewing rear bonded rubber bush for suspension link
  30
• 3.12 Removing and installing anti-roll bar
  32
• 3.13 Removing and installing rubber bush for anti-roll bar
  34
• 4 Assembly overview: wheel bearing
  37
• 4.1 Pulling out and pulling in wheel hub with wheel bearing
  38
• 4.2 Removing and installing wheel bearing housing
  43
• 5 Assembly overview: suspension strut
  47
• 5.1 Removing and installing suspension strut
  48
• 5.2 Repairing front suspension strut
  53
• 6 Removing and installing drive shafts
  57
• 6.1 Removing and installing drive shaft with constant velocity joint
  57
• 6.2 Removing and installing drive shaft with triple roller joint AAR 2000 (bolted-on)
  59
• 7 Repairing drive shafts - overview of drive shafts
  61
• 7.1 Heat shields for drive shafts
  62
• 8 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint
  63
• 8.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint
  65
• 8.2 Checking outer constant velocity joint
  70
• 8.3 Checking inner constant velocity joint
  71
• 9 Assembly overview: drive shaft with VL107 constant velocity joint
  73
• 9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  75
• 10 Assembly overview: drive shaft with triple roller joint AAR 2000/108
  80
• 10.1 Dismantling and assembling drive shaft with triple roller joint AAR 2000/108
  82
• Rear suspension
  90
• 1 Evaluating accident vehicles
  90
• 2 Repairing rear axle
  91
• 2.1 Overview - rear axle
  91
• 2.2 Rear axle in unladen position
  93
• 3 Assembly overview: axle beam, drum brake
  95
• 3.1 Removing and installing rear axle
  97
• 3.2 Removing and installing bonded rubber bush
  101
• 3.3 Removing and installing coil spring, vehicles with small rear silencer
  107
• 3.4 Removing and installing coil spring, vehicles with large rear silencer
  108
• 4 Assembly overview: axle body, disc brake
  111
• 5 Assembly overview: shock absorber
  113
• 5.1 Removing and installing shock absorbers
  114
• 6 Assembly overview: wheel bearings, drum brake
  116
• 6.1 Removing and installing wheel hub with wheel bearing, vehicles with drum brakes
  117
• 7 Assembly overview: wheel bearings, disc brake
  120
• Self-levelling suspension
  123
• 1 Assembly overview: rear left vehicle level sender G76 , front-wheel drive
  123
• 1.1 Removing and installing rear left vehicle level sender G76
  123
• Wheels, tyres, vehicle geometry
  125
• 1 Evaluating accident vehicles
  125
• 2 Specified torques for wheel bolts
  126
• 3 Removing and fitting tyres with run-flat properties to wheel rims
  127
• 3.1 Notes on safety and prerequisites
  127
• 3.2 Fittings instructions
  127
• 3.3 Pressing tyre off wheel rim
  128
• 3.4 Removing tyre from wheel
  129
• 3.5 Fitting tyre to wheel rim
  130
• 4 Tyre pressure monitor display
  133
• 5 Vehicle alignment check
  135
• 5.1 General information
  135
• 5.2 Conditions for testing
  137
• 5.3 Test preparations
  137
• 5.4 Wheel alignment specifications
  138
• 5.5 Transverse vehicle inclination “zero position”
  140
• 5.6 Overview - wheel alignment procedure
  140
• 5.7 Correcting front axle camber
  141
• 5.8 Check rear axle camber
  142
• 5.9 Check rear axle toe
  142
• 5.10 Adjusting front axle toe
  143
• 5.11 Checking left and right-hand wheel lock
  143
• 5.12 Vehicle data sticker
  144
• 6 Wheels, tyres
  145
• 6.1 Models with breakdown set
  145
• 6.2 Tyre sealant
  145
• 6.3 Removing a tyre
  145
• 6.4 Fitting a new tyre
  146
• 6.5 Tyre sealant disposal
  146
• 7 Instructions for changing or fitting wheels
  147
• 7.1 Fitting wheels
  148
• 8 Protecting wheel centring seat against corrosion
  149
• 9 Wheel change, installation requirements
  150
• 10 Vibration due to wheels/tyres - causes and rectification
  152
• 10.1 Causes of rough running
  152
• 10.2 Balancing wheels
  152
• 10.3 Conducting a road test before balancing wheels
  153
• 10.4 Balancing wheels on stationary wheel balancing machine
  153
• 10.5 Vibration control system VAS 6230 A
  156
• 10.6 Finish balancer
  156
• 10.7 Radial and lateral runout of wheels and tyres
  157
• 10.9 Checking radial and lateral run-out on wheel rim
  158
• 10.10 Matching
  159
• 10.11 Flat spots caused by storage or handling
  160
• Steering
  162
• 1 Evaluating accident vehicles
  162
• 2 General repair instructions
  163
• 2.1 Steering rack
  163
• 2.2 Gaskets and seals
  163
• 2.3 Nuts and bolts
  163
• 2.4 Electrical components
  164
• 2.5 Guided fault finding, vehicle self-diagnosis and test instruments
  164
• 3 Steering column
  165
• 3.1 Removing and installing steering wheel
  165
• 3.2 Assembly overview: steering column, left-hand drive
  168
• 3.3 Removing and installing steering column, left-hand drive vehicle
  168
• 3.4 Assembly overview: steering column, right-hand drive
  173
• 3.5 Removing and installing steering column, right-hand drive vehicle
  174
• 3.6 Handling and transporting steering column
  179
• 4 Electro-hydraulic power steering
  181
• 4.2 Removing and installing power-assisted steering rack, left-hand drive vehicle
  182
• 4.3 Removing and installing power steering sensor G250 , left-hand drive vehicle
  188
• 4.4 Assembly overview for electrohydraulic power steering, right-hand drive vehicle
  188
• 4.5 Removing and installing power steering rack, right-hand drive vehicle
  190
• 4.6 Removing and installing power steering sensor G250 , right-hand drive vehicle
  195
• 5 Repairing power steering rack
  197
• 5.1 Assembly overview: power steering rack, left-hand drive vehicle
  197
• 5.2 Assembly overview: power steering rack, right-hand drive vehicle
  199
• 5.3 Removing and installing track rod
  201
• 5.4 Checking play, security and boots of track rod ends
  202
• 5.5 Checking and adjusting left track rod length
  202
• 5.6 Allocation of track rod ball joints
  203
• 5.7 Allocation of track rod ball joints for GTI and R WRC
  203
• 5.8 Determining centre position of steering rack
  204
• 5.9 Adjusting steering rack
  204
• 6 Motor/pump unit
  205
• 6.1 Assembly overview: engine pump unit
  205
• 6.2 Removing and installing motor/pump unit
  206
• 6.3 Renewing reservoir for motor/pump unit
  209
• 6.4 Checking delivery pressure of motor/pump unit
  211
• 7 Bleeding steering system, checking for leaks and checking fluid level
  215
• 7.1 Bleeding steering system
  215
• 7.2 Check steering system for leaks
  215
• 7.3 Checking hydraulic fluid level of power steering
  216