Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Safety indications
  1
• 1.1 Safety measures for work in vehicles with Start-Stop system
  1
• 1.2 Safety measures for work in the auxiliary frame
  1
• 2 Assessment of crashed vehicles
  2
• 2.1 Crashed vehicles - running gear inspection check-list
  2
• 3 Disposal of gas struts
  4
• 3.1 Disposal of front gas struts
  4
• 3.2 Disposal of rear gas struts
  5
• 4 Repair instructions
  8
• 4.1 Shock absorbers - leaks
  8
• 4.2 Shock absorbers - noises
  8
• 4.3 Shock absorbers - test
  9
• 4.4 Steering box
  9
• 4.5 Seals, ring seals
  10
• 4.6 Bolts, nuts
  10
• 4.7 Electric components
  10
• 4.8 Raise the axle of the unloaded vehicle with coil spring
  11
• Front suspension
  17
• 1 Front axle
  17
• 1.1 Front axle - general assembly overview
  17
• 2 Auxiliary frame
  20
• 2.1 Auxiliary frame - general assembly overview
  20
• 2.2 Auxiliary frame without steering rack - remove and install
  20
• 2.3 Auxiliary frame with steering rack - remove and install
  23
• 2.4 Auxiliary frame - position
  29
• 2.5 Auxiliary frame - Lower
  33
• 3 Anti-roll bar
  37
• 3.1 Anti-roll bar - general assembly overview
  37
• 3.2 Anti-roll bar - remove and install
  37
• 3.3 Coupling rod - remove and install
  40
• 4 Lower wishbone, swivel joint
  42
• 4.1 Lower wishbone, swivel joint - Assembly overview
  42
• 4.2 Lower wishbone - remove and install
  43
• 4.3 Check the drive shaft
  46
• 4.4 Swivel guide - remove and install
  47
• 4.5 Lower front metal/rubber bearings of the wishbone - replace
  50
• 5 Suspension strut, upper wishbone
  58
• 5.1 Suspension strut, upper wishbone - Assembly overview
  58
• 5.2 Suspension strut - remove and install
  60
• 5.3 Suspension strut - repair
  70
• 6 Wheel roller bearing
  73
• 6.1 Wheel bearing - general overview of assembly
  73
• 6.2 Wheel bearing case - remove and install
  73
• 6.3 Hub and wheel bearing - remove and install
  80
• 7 Drive shaft
  89
• 7.1 Drive shaft - assembly overview
  89
• 7.2 Drive shaft - assembly overview
  89
• 7.3 Drive shaft - remove and install
  93
• 7.4 Joint - remove and install
  109
• 7.5 Drive shaft heat shield - remove and install
  113
• 7.6 Drive shaft - assemble and disassemble
  114
• 7.7 External constant velocity joint - check
  127
• 7.8 Internal constant velocity joint - check (Only for model 1.6 MSi)
  129
• Rear suspension
  132
• 1 Axle beam
  132
• 1.1 Axle beam - assembly overview
  132
• 1.2 Axle beam - replace the bonded rubber bush
  132
• 2 Suspension strut/shock absorber, spring
  142
• 2.1 Suspension strut/shock absorber, spring - assembly overview
  142
• 2.2 Shock absorber - remove and install
  143
• 2.3 Shock absorber - repair
  145
• 2.4 Spring - remove and install
  147
• 3 Rear axle
  150
• 3.1 Rear axle - overview
  150
• 3.2 Rear axle - remove and install
  151
• 4 Wheel roller bearing
  157
• 4.1 Wheel bearing - general overview of assembly
  157
• 4.2 Wheel hub/wheel bearing unit - remove and install
  158
• Self-levelling suspension
  166
• 1 Vehicle level sender
  166
• 1.1 Rear vehicle level sender - assembly overview
  166
• 1.2 Rear vehicle level sender G76 – remove and install
  166
• Wheels, tyres, vehicle geometry
  169
• 1 Tyre monitoring system
  169
• 1.1 Tyre Pressure Monitoring System - system description
  169
• 2 Axle geometry check
  171
• 2.1 Axle geometry check instructions
  171
• 2.2 Preliminary testing conditions
  172
• 2.3 Preparation for alignment
  172
• 2.4 Nominal vehicle geometry alignment values
  174
• 2.5 Place the vehicle in initial position to check geometry
  175
• 2.6 Axle alignment work procedure
  176
• 2.7 Axle geometry measurement requirement
  177
• 2.8 Vehicle data tag
  178
• 2.9 Adjust front axle camber angle
  178
• 2.10 Adjust the rear axle camber angle
  180
• 2.11 Adjust the rear axle toe-out
  180
• 2.12 Adjust front axle toe-out angle
  180
• 2.13 Check the maximum steering angle
  181
• 3 Tightening torques of wheel bolts
  183
• Steering
  184
• 1 Steering wheel
  184
• 1.1 Steering wheel - assembly overview
  184
• 1.2 Steering wheel - remove and install
  184
• 2 Steering column
  187
• 2.1 Steering column - assembly overview
  187
• 2.2 Steering column - remove and install
  189
• 2.3 Handling and transporting the steering column
  198
• 2.4 Intermediate steering column axle - remove and install
  201
• 2.5 Steering column - repair
  202
• 2.6 Power steering control unit J500 - remove and install
  204
• 3 Sensors
  210
• 3.1 Steering angle sensor G85 - remove and install
  210
• 4 Steering rack
  211
• 4.1 Steering rack - general overview of assembly
  211
• 4.2 Steering box - remove and install
  214
• 4.3 Track rod - remove and install
  220
• 4.4 Track rod ball joint - remove and install
  224