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 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 box
  20
• 3.8 Removing and installing subframe with steering box
  24
• 3.9 Repairing subframe
  29
• 3.10 Checking swivel joint
  37
• 3.11 Removing and installing swivel joint
  38
• 3.12 Removing and installing suspension link with mounting bracket
  40
• 3.14 Renewing bonded rubber bush for suspension link
  49
• 3.15 Renewing mounting bracket with suspension link bush
  51
• 3.16 Removing and installing anti-roll bar
  53
• 4 Assembly overview: wheel bearing
  59
• 4.1 Removing and installing wheel bearing unit
  61
• 4.2 Removing and installing wheel bearing housing
  63
• 5 Assembly overview: suspension strut
  68
• 5.1 Removing and installing suspension strut
  69
• 5.2 Repairing suspension strut
  75
• 6 Removing and installing drive shafts
  77
• 6.1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  77
• 6.3 Removing and installing drive shaft with constant velocity joint
  80
• 6.4 Removing and installing drive shafts with triple roller joint AAR3300i
  83
• 7 Repairing drive shafts - overview of drive shafts
  87
• 7.1 Heat shields for drive shafts
  88
• 8 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint
  89
• 8.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint
  91
• 8.2 Checking outer constant velocity joint
  95
• 8.3 Checking inner constant velocity joint
  96
• 9 Assembly overview: drive shaft with VL107 constant velocity joint
  99
• 9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  101
• 10 Assembly overview: drive shaft with triple roller joint AAR3300i
  106
• 10.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i
  108
• Rear suspension
  114
• 1 Evaluating accident vehicles
  114
• 2 Repairing rear suspension (front-wheel drive)
  115
• 2.1 Overview - rear axle
  115
• 2.2 Rear axle in unladen position
  116
• 3 Assembly overview: subframe, transverse link, track rod (front-wheel drive)
  118
• 3.1 Assembly overview: rear left vehicle level sender G76 , front-wheel drive
  120
• 3.2 Removing and installing rear left vehicle level sender G76 (front-wheel drive)
  120
• 3.3 Fixing position of subframe
  121
• 3.4 Lowering rear axle
  122
• 3.5 Removing and installing rear axle
  125
• 3.6 Removing and installing upper transverse link
  129
• 3.7 Removing and installing lower transverse link
  131
• 3.8 Removing and installing track rod
  132
• 4 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)
  136
• 4.1 Removing and installing wheel bearing housing
  137
• 4.2 Renewing bonded rubber bush for wheel bearing housing
  140
• 4.3 Removing and installing wheel bearing/wheel hub unit
  143
• 4.4 Removing and installing wheel bearing pre-seal
  146
• 4.5 Removing and installing trailing arm with mounting bracket
  147
• 4.6 Repairing trailing arm
  151
• 5 Assembly overview: shock absorber, coil spring
  154
• 5.1 Removing and installing coil spring
  154
• 5.2 Removing and installing shock absorbers
  156
• 5.3 Repairing shock absorber
  157
• 6 Assembly overview: anti-roll bar
  160
• 6.1 Removing and installing anti-roll bar
  160
• 7.1 Removing and installing trim for rear axle
  164
• 8 Repairing rear suspension (four-wheel drive)
  166
• 8.1 Overview - rear axle
  166
• 8.2 Rear axle in unladen position
  168
• 9 Assembly overview: subframe, final drive (four-wheel drive)
  170
• 9.1 Removing and installing rear axle
  170
• 9.2 Repairing subframe, up to Week 26/2012
  175
• 9.3 Repairing subframe, as of Week 27/2012
  183
• 10 Assembly overview: transverse link, track rod (four-wheel drive)
  197
• 10.1 Overview - rear left vehicle level sender G76
  200
• 10.2 Renew vehicle level sender in vehicle
  200
• 10.3 Removing and installing upper transverse link
  201
• 10.4 Removing and installing lower transverse link
  203
• 10.5 Removing and installing track rod
  205
• 11 Assembly overview: wheel bearing housing, trailing arm (four-wheel drive)
  208
• 11.1 Removing and installing wheel bearing housing
  210
• 11.2 Renewing bonded rubber bush for wheel bearing housing
  213
• 11.3 Removing and installing wheel bearing/wheel hub unit
  216
• 11.4 Removing and installing trailing arm with mounting bracket
  218
• 11.5 Repairing trailing arm
  221
• 12 Assembly overview: shock absorber, coil spring (four-wheel drive)
  224
• 12.1 Removing and installing coil spring
  224
• 12.2 Removing and installing shock absorbers
  226
• 12.3 Repairing shock absorber
  228
• 13 Assembly overview: anti-roll bar (four-wheel drive)
  231
• 13.1 Removing and installing anti-roll bar
  231
• 14 Assembly overview: drive shaft
  234
• 14.1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  236
• 14.3 Removing and installing drive shaft
  239
• 14.4 Dismantling and assembling drive shaft
  241
• 14.5 Checking outer constant velocity joint
  246
• 14.6 Checking inner constant velocity joint
  247
• Wheels, tyres, vehicle geometry
  250
• 1 Evaluating accident vehicles
  250
• 2 Specified torque for fitting wheels
  251
• 3 Fitting wheel and tyre
  252
• 3.1 General information
  252
• 3.2 Fittings instructions
  252
• 4 Removing and fitting tyres (wheels with tyre pressure monitoring)
  254
• 4.2 Wheel change
  254
• 4.3 Pressing tyre off wheel rim
  255
• 4.4 Removing tyre from wheel
  256
• 4.5 Fitting tyre to wheel rim
  256
• 5 Removing and fitting tyres with run-flat properties to wheel rims
  258
• 5.1 Notes on safety
  258
• 5.2 Fittings instructions
  258
• 5.3 Pressing tyre off wheel rim
  259
• 5.4 Removing tyre from wheel
  260
• 5.5 Fitting tyre to wheel rim
  261
• 6 Tyre pressure monitor display
  264
• 6.1 General
  264
• 6.2 System fault in the ABS system
  265
• 6.3 Perform basic setting
  265
• 7 Tyre pressure monitor
  266
• 7.1 Button behaviour
  266
• 7.2 Assembly overview: tyre pressure sensor
  267
• 7.3 Removing and installing tyre pressure sensor
  268
• 8 Wheel alignment
  270
• 8.1 General
  270
• 8.2 Test prerequisites
  272
• 8.3 Test preparations
  272
• 8.4 Wheel alignment specifications
  273
• 8.5 Overview - wheel alignment procedure
  274
• 8.6 Correcting front axle camber
  275
• 8.7 Adjusting camber on rear axle
  277
• 8.8 Adjusting toe at rear axle
  278
• 8.9 Adjusting front axle toe
  279
• 8.10 Basic setting for steering angle sender G85
  280
• 8.11 Vehicle data sticker
  280
• 9 Wheels, tyres
  282
• 9.1 Models with breakdown set
  282
• 9.2 Tyre sealant
  282
• 9.3 Removing a tyre
  282
• 9.4 Fitting a new tyre
  283
• 9.5 Tyre sealant disposal
  283
• 10 Instructions for changing or fitting wheels
  284
• 10.1 Fitting wheels
  285
• 11 Protecting wheel centring seat against corrosion
  286
• 12 Rough running due to wheels/tyres - causes and rectification
  287
• 12.1 Causes of rough running
  287
• 12.2 Balancing wheels
  287
• 12.3 Conducting a road test before balancing wheels
  287
• 12.4 Balancing wheels on stationary wheel balancing machine
  288
• 12.5 Vibration control system VAS 6230 A
  291
• 12.6 Finish balancer
  291
• 12.7 Radial and lateral runout of wheels and tyres
  292
• 12.9 Checking radial and lateral runout on wheel rim
  293
• 12.10 Matching
  294
• 12.11 Flat spots caused by storage or handling
  295
• Steering
  297
• 1 Evaluating accident vehicles
  297
• 2 General repair instructions
  298
• 2.1 Steering box
  298
• 2.2 Gaskets and seals
  298
• 2.3 Nuts and bolts
  298
• 2.4 Electrical components
  299
• 2.5 Guided fault-finding, vehicle self-diagnosis and test instruments
  299
• 3 Steering wheel, steering column
  300
• 3.1 Removing and installing steering wheel
  300
• 3.2 Assembly overview: steering column, left-hand drive, vehicle with no knee airbag
  303
• 3.4 Assembly overview: steering column, left-hand drive, vehicle with knee airbag . .
  311
• 3.5 Removing and installing steering column, left-hand drive, vehicle with knee airbag
  312
• 3.6 Assembly overview: steering column, right-hand drive
  321
• 3.7 Removing and installing steering column, right-hand drive vehicle
  322
• 3.8 Handling and transporting steering column
  328
• 3.9 Checking steering column for damage
  329
• 4 Electromechanical steering box
  331
• 4.1 Assembly overview - electromechanical steering box, left-hand drive
  331
• 4.2 Assembly overview - electromechanical steering box, right-hand drive
  332
• 4.3 Removing and installing steering box, left-hand drive vehicle
  333
• 4.4 Removing and installing steering box, right-hand drive vehicle
  341
• 5 Repairing electromechanical steering box
  350
• 5.1 Assembly overview: electromechanical steering box
  350
• 5.2 Removing and installing boot
  351
• 5.3 Removing and installing track rod
  353