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 Raising wheel bearing to unladen position
  5
• 3 Repairing front suspension
  7
• 4 I: Assembly overview: subframe, anti-roll bar, lower suspension link
  9
• 4.1 Repairing thread in longitudinal member
  10
• 4.2 Fixing position of subframe
  11
• 4.3 Removing and installing subframe
  13
• 4.4 Repairing subframe
  19
• 4.5 Removing and installing subframe front bonded rubber bush
  22
• 4.6 Removing and installing subframe rear bonded rubber bush
  24
• 4.7 Checking swivel joint
  25
• 4.8 Removing and installing lower suspension link
  25
• 5 Assembly overview: disengageable anti-roll bar
  36
• 5.1 Removing and installing disengageable anti-roll bar
  37
• 5.3 Bleeding disengageable anti-roll bar
  41
• 6 II: Assembly overview: front suspension
  43
• 6.1 Repairing upper suspension link
  45
• 6.2 Removing and installing suspension strut
  47
• 6.3 Removing and installing air spring strut
  49
• 6.4 Charging air spring strut
  54
• 7 III: Assembly overview: wheel bearing
  61
• 7.1 Removing and installing wheel hub with bearing for 16" inch wheels
  62
• 7.2 Removing and installing wheel bearing for 17"/18"/18" plus running gear
  65
• 8 IV: Assembly overview: suspension strut
  71
• 8.1 Allocation of lower spacer
  71
• 8.2 Repairing front coil spring suspension strut
  71
• 9 V - Front air spring strut
  75
• 9.1 Instructions for repairing air spring struts
  75
• 9.2 Air spring strut
  75
• 9.3 Residual pressure valve
  75
• 9.4 Gaskets and seals
  76
• 9.5 Nuts and bolts
  76
• 9.6 Front air spring strut components
  76
• 9.7 Assembly overview - front air spring strut
  78
• 9.8 Repairing front air spring strut
  78
• 9.9 Removing and installing residual pressure valve
  85
• 10 Assembly overview: drive shaft
  87
• 10.1 Removing and installing jointed shaft
  88
• 10.2 Dismantling and assembling drive shaft
  91
• 10.3 Checking outer joint
  95
• Rear suspension
  97
• 1 Appraisal of accident vehicles
  97
• 2 Repairing rear suspension
  98
• 3 I - Assembly overview: subframe, anti-roll bar, stone deflector
  100
• 3.1 Repairing thread in rear longitudinal member
  101
• 3.2 Fixing position of subframe
  102
• 3.3 Removing and installing subframe
  103
• 3.4 Repairing subframe
  107
• 4 Removing and installing rear vehicle level senders G76/G77
  111
• 5 Assembly overview: disengageable anti-roll bar
  113
• 5.1 Removing and installing disengageable anti-roll bar
  114
• 5.3 Bleeding disengageable anti-roll bar
  117
• 6 Assembly overview: motor/pump unit for disengageable anti-roll bars
  119
• 6.1 Removing and installing motor/pump unit
  121
• 6.2 Removing and installing anti-roll bar uncoupling control unit J742
  123
• 6.3 Line routing for disengageable anti-roll bars
  123
• 7 II - Assembly overview: suspension link, track rod
  125
• 8 III - Assembly overview: rear suspension
  128
• 8.1 Removing and installing suspension strut
  129
• 8.2 Removing and installing air spring strut
  130
• 8.3 Charging air spring strut
  132
• 9 IV - Assembly overview: wheel bearing
  134
• 9.1 Pressing wheel hub with wheel bearing for 16" running gear out and in
  135
• 9.2 Pressing wheel bearing for 17"/18"/18" plus running gear out and in
  138
• 9.3 Repairing wheel bearing housing
  144
• 10 V - Assembly overview: suspension strut
  148
• 10.1 Allocation of lower spacer
  148
• 10.2 Repairing rear coil spring strut
  149
• 11 VI - Rear air spring strut
  152
• 11.1 Instructions for repairing air spring struts
  152
• 11.2 Air spring strut
  152
• 11.3 Residual pressure valve
  152
• 11.4 Gaskets and seals
  153
• 11.5 Nuts and bolts
  153
• 11.6 Rear air spring strut components
  153
• 11.7 Assembly overview - rear air spring strut
  155
• 11.8 Repairing rear air spring strut
  155
• 11.9 Removing and installing residual pressure valve
  162
• 12 VII - Assembly overview: drive shaft
  164
• 12.1 Removing and installing rear drive shaft
  165
• 12.2 Dismantling and assembling drive shaft
  169
• 12.3 Checking inner joint
  170
• Self-levelling suspension
  172
• 1 Appraisal of accident vehicles
  172
• 2 Jacking mode
  173
• 3 Repairing self-levelling suspension
  174
• 3.1 Fault finding, air spring strut and self-levelling suspension
  174
• 3.2 Self-levelling suspension components and fitting locations
  176
• 3.3 Assembly overview: air supply unit with solenoid valve block
  179
• 3.4 Removing and installing air supply unit without solenoid valve block
  180
• 3.5 Removing and installing air supply unit with solenoid valve block
  182
• 3.6 Assembly overview - air supply unit
  183
• 3.7 Renewing piston ring
  184
• 3.8 Removing and installing adaptive suspension control unit J197
  188
• 3.9 Repairing air line
  189
• 3.10 Basic settings for self-levelling suspension
  190
• 3.11 Measuring ride height
  190
• Wheels, tyres, vehicle geometry
  191
• 1 Appraisal of accident vehicles
  191
• 2 Torque settings for wheel bolts and tyre assembly
  192
• 2.1 Specified torque for wheel bolts
  192
• 2.2 Fitting tyre
  192
• 3 Removing and fitting tyres (wheels with tyre pressure monitoring)
  193
• 3.2 Wheel change
  193
• 3.3 Fittings instructions
  194
• 3.4 Pressing tyre off wheel rim
  195
• 3.5 Removing tyre from wheel
  196
• 3.6 Fitting tyre to wheel rim
  196
• 4 Protecting wheel centring seat against corrosion
  198
• 5 Wheel alignment
  199
• 5.1 General
  199
• 5.2 Wheel alignment specifications
  199
• 6 Repairing tyre pressure monitor, 1st generation
  202
• 6.1 Component overview - tyre pressure monitor
  202
• 6.2 Component overview - tyre pressure sensor and metal valve
  203
• 6.3 Removing and installing tyre pressure sensor
  204
• 6.4 Removing and installing metal valve
  204
• 6.5 Removing and installing front tyre pressure monitor aerials R59/R60
  205
• 6.6 Removing and installing rear tyre pressure monitor aerials R61/R62
  206
• 6.7 Removing and installing tyre pressure monitor control unit J502
  207
• 6.8 Fitting tyres on wheels with tyre pressure monitors
  207
• 6.9 Storing current tyre inflation pressure
  208
• 7 Repairing tyre pressure monitor, 2nd generation
  209
• 7.1 Component overview - tyre pressure monitor
  209
• 7.2 Component overview - tyre pressure sensor and metal valve
  210
• 7.3 Removing and installing tyre pressure sensor
  211
• 7.4 Removing and installing metal valve
  211
• 7.5 Removing and installing tyre pressure monitor sender unit in front left wheel housing G431
  212
• 7.6 Removing and installing tyre pressure monitor sender unit in front right wheel housing G432
  213
• 7.7 Removing and installing tyre pressure monitor sender unit in rear left wheel housing G433
  214
• 7.8 Removing and installing tyre pressure monitor sender unit in rear right wheel housing G434
  214
• 7.9 Removing and installing tyre pressure monitor aerial R207
  215
• 7.10 Removing and installing tyre pressure monitor control unit J502
  216
• 7.11 Fitting tyres on wheels with tyre pressure monitors
  216
• 8 Adaptive Cruise Control (ACC)
  218
• 8.1 General information on ACC calibration
  218
• 8.2 ACC calibration during vehicle alignment
  218
• 8.3 ACC calibration without prior vehicle alignment
  220
• 9 Wheels, tyres
  223
• 9.1 Models with breakdown set
  223
• 9.2 Tyre sealant
  223
• 9.3 Removing a tyre
  223
• 9.4 Fitting a new tyre
  224
• 9.5 Tyre sealant disposal
  224
• 10 Instructions for changing or fitting wheels
  225
• 10.1 Fitting wheels
  226
• 11 Protecting wheel centring seat against corrosion
  227
• 12 Rough running due to wheels/tyres - causes and rectification
  228
• 12.1 Causes of rough running
  228
• 12.2 Balancing wheels
  228
• 12.3 Conducting a road test before balancing wheels
  228
• 12.4 Balancing wheels on stationary wheel balancing machine
  229
• 12.5 Vibration control system
  232
• 12.6 Finish balancer
  232
• 12.7 Radial and lateral runout of wheels and tyres
  233
• 12.9 Checking radial and lateral runout on wheel rim
  234
• 12.10 Matching
  235
• 12.11 Flat spots caused by storage or handling
  236
• Steering
  238
• 1 Appraisal of accident vehicles
  238
• 2 Steering column
  239
• 2.1 Assembly overview: steering column
  239
• 2.2 Removing and installing steering column
  240
• 2.3 Removing and installing sealing boot
  243
• 3 Power steering
  244
• 3.1 Assembly overview: power steering, left-hand drive vehicle
  244
• 3.2 Removing and installing power steering box, left-hand drive vehicle
  245
• 3.3 Assembly overview: power steering, right-hand drive vehicle
  247
• 3.4 Removing and installing power steering box, right-hand drive vehicle
  249
• 4 Repairing power steering box
  253
• 4.1 Assembly overview: steering box
  253
• 4.2 Removing and installing track rod
  254
• 5 Vane pump, 5-cylinder diesel engine
  257
• 5.1 Checking vane pump delivery pressure, 5-cylinder diesel engine
  257
• 5.2 Assembly overview: vane pump, 5-cylinder diesel engine
  259
• 5.3 Removing and installing vane pump, 5-cylinder diesel engine
  260
• 6 Vane pump, 6-cylinder diesel engine to model year 2008
  265
• 6.2 Assembly overview: vane pump, 6-cylinder diesel engine to model year 2008
  268
• 6.3 Removing and installing vane pump, 6-cylinder diesel engine to model year 2008
  269
• 7 Vane pump, 6-cylinder diesel engine from model year 2009
  272
• 7.1 Checking delivery pressure of vane pump, 6-cylinder diesel engine from model year 2009
  272
• 7.2 Assembly overview: vane pump, 6-cylinder diesel engine from model year 2009
  276
• 8 Vane pump, 6-cylinder petrol engine
  281
• 8.1 Checking vane pump delivery pressure, 6-cylinder petrol engine
  281
• 8.2 Assembly overview: vane pump, 6-cylinder petrol engine
  283
• 8.3 Removing and installing vane pump, 6-cylinder petrol engine
  284
• 9 Vane pump, 8-cylinder petrol engine
  287
• 9.1 Checking vane pump delivery pressure, 8-cylinder petrol engine
  287
• 9.2 Assembly overview: vane pump, 8-cylinder petrol engine
  289
• 9.3 Removing and installing vane pump, 8-cylinder petrol engine
  290
• 10 Vane pump, V8 FSI engine
  294
• 10.1 Checking vane pump delivery pressure, V8 FSI engine
  294
• 10.2 Assembly overview - V8 FSI engine
  297
• 10.3 Removing and installing vane pump, V8 FSI engine
  299
• 11 Vane pump, 10-cylinder diesel engine
  304
• 11.1 Checking vane pump delivery pressure, 10-cylinder diesel engine
  304
• 11.2 Assembly overview: vane pump, 10-cylinder diesel engine
  307
• 11.3 Removing and installing vane pump, 10-cylinder diesel engine
  309
• 12 Vane pump, W12 petrol engine
  311
• 12.1 Checking vane pump delivery pressure, W12 petrol engine
  311
• 12.2 Assembly overview - vane pump, W12 petrol engine
  313
• 12.3 Removing and installing vane pump, W12 petrol engine
  314
• 13 Removing and installing oil cooler
  319
• 14 Bleeding steering system and checking for leaks
  321
• 14.1 Bleeding steering system
  321
• 14.2 Checking steering system for leaks
  321