Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 1.2 Safety precautions when working on high-voltage system
  1
• 1.3 Safety precautions when working in the vicinity of high-voltage components
  2
• 1.4 Safety precautions when working on subframe
  2
• 2 Repair notes
  3
• 2.1 Leaks at shock absorbers
  3
• 2.2 Noises from shock absorbers
  3
• 2.3 Checking shock absorbers when removed
  4
• 2.4 Steering rack
  4
• 2.5 Gaskets and seals
  5
• 2.6 Nuts and bolts
  5
• 2.7 Electrical components
  5
• 2.8 Raising suspension to unladen position (vehicles with coil springs)
  5
• 3 Evaluating accident vehicles
  9
• 3.1 Check list for evaluating running gear on accident vehicles
  9
• 4 Disposal
  11
• 4.1 Releasing gas and draining front gas-filled shock absorbers
  11
• 4.2 Releasing gas and draining rear gas-filled shock absorbers
  13
• Front suspension
  14
• 1 Front axle
  14
• 1.1 Overview of fitting locations – front axle
  14
• 2 Subframe
  15
• 2.1 Assembly overview – subframe
  15
• 2.2 Removing and installing subframe without steering rack
  17
• 2.3 Removing and installing subframe with steering rack
  22
• 2.4 Repairing subframe
  37
• 2.5 Removing and installing anti-roll bar
  48
• 2.6 Removing and installing coupling rod
  54
• 2.7 Repairing thread in longitudinal member
  55
• 2.8 Fixing subframe in position
  55
• 2.9 Lowering subframe
  59
• 3 Suspension strut, upper suspension link
  64
• 3.1 Assembly overview - suspension strut, upper suspension link
  64
• 3.2 Removing and installing suspension strut
  65
• 3.3 Repairing suspension strut
  76
• 4 Lower suspension link, swivel joint
  80
• 4.1 Assembly overview - lower suspension link, swivel joint
  80
• 4.2 Removing and installing lower suspension link
  82
• 4.3 Checking swivel joint
  95
• 4.4 Removing and installing swivel joint
  96
• 4.5 Renewing bonded rubber bush for lower suspension link
  101
• 5 Wheel bearing
  109
• 5.1 Assembly overview – wheel bearing assembly
  109
• 5.2 Removing and installing wheel bearing housing
  109
• 5.3 Removing and installing wheel bearing unit
  116
• 6 Drive shaft
  120
• 6.1 Overview - drive shaft
  120
• 6.2 Assembly overview – drive shaft
  121
• 6.3 Removing and installing drive shaft
  127
• 6.4 Loosening and tightening threaded connections of drive shaft
  145
• 6.5 Removing and installing drive shaft heat shield
  146
• 6.6 Dismantling and assembling drive shaft
  147
• 6.7 Checking outer constant velocity joint
  166
• 6.8 Checking inner constant velocity joint
  167
• Rear suspension
  171
• 1 Rear axle
  171
• 1.1 Overview – rear axle
  171
• 1.2 Lowering rear axle
  175
• 1.3 Removing and installing rear axle
  183
• 1.4 Removing and installing shield for rear axle, vehicles with multi-link suspension
  197
• 2 Axle beam
  198
• 2.1 Assembly overview – axle beam
  198
• 2.2 Renewing bonded rubber bush for axle beam
  198
• 2.3 Assembly overview - attachments for torsion beam axle
  207
• 3 Subframe
  208
• 3.1 Assembly overview – subframe
  208
• 3.2 Assembly overview - add-on parts for subframe
  209
• 3.3 Fixing subframe in position
  210
• 3.4 Repairing subframe
  225
• 4 Anti-roll bar
  239
• 4.1 Assembly overview – anti-roll bar
  239
• 4.2 Removing and installing anti-roll bar
  240
• 4.3 Removing and installing coupling rod
  241
• 5 Suspension link, track rod
  245
• 5.1 Assembly overview - transverse link
  245
• 5.2 Assembly overview – track rod
  249
• 5.3 Removing and installing upper transverse link
  251
• 5.4 Removing and installing lower transverse link
  254
• 5.5 Removing and installing track rod
  255
• 6 Suspension strut, shock absorber, spring
  257
• 6.1 Assembly overview - suspension strut, shock absorber, spring
  257
• 6.2 Removing and installing shock absorber
  259
• 6.3 Repairing shock absorber
  266
• 6.4 Removing and installing spring
  268
• 7 Wheel bearing assembly, trailing arm
  278
• 7.1 Assembly overview – wheel bearing assembly
  278
• 7.2 Assembly overview - trailing arm
  283
• 7.3 Removing and installing wheel bearing housing
  284
• 7.4 Removing and installing wheel bearing unit
  295
• 7.5 Renewing bonded rubber bush for wheel bearing housing
  305
• 7.6 Removing and installing trailing arm with mounting bracket
  310
• 7.7 Repairing trailing arm, vehicles with standard bushes
  313
• 8 Drive shaft
  319
• 8.1 Assembly overview – drive shaft
  319
• 8.2 Removing and installing drive shaft
  321
• 8.3 Dismantling and assembling drive shaft
  326
• 8.4 Loosening and tightening threaded connections of drive shaft
  332
• 8.5 Checking outer constant velocity joint
  333
• 8.6 Checking inner constant velocity joint
  335
• Self-levelling suspension
  338
• 1 Electronically controlled damping system
  338
• 1.1 Assembly overview - electronically controlled damping system
  338
• 1.2 Removing and installing electronically controlled damping control unit J250
  342
• 1.3 Removing and installing front body acceleration senders G341/G342
  343
• 1.4 Removing and installing rear body acceleration sender G343
  344
• 2 Vehicle level sender
  346
• 2.1 Assembly overview – front vehicle level senders
  346
• 2.2 Assembly overview – rear vehicle level senders
  347
• 2.3 Removing and installing front vehicle level senders G78/G289
  349
• 2.4 Removing and installing rear vehicle level senders G76/G77
  351
• Wheels, tyres, vehicle geometry
  356
• 1 Wheel alignment
  356
• 1.1 Notes for wheel alignment
  356
• 1.2 Conditions for testing
  357
• 1.3 Test preparations
  357
• 1.4 Specifications for wheel alignment
  359
• 1.5 Setting vehicle to initial position for wheel alignment
  362
• 1.6 Wheel alignment procedure
  362
• 1.7 Necessity of wheel alignment
  364
• 1.8 Adjusting camber at front wheels
  366
• 1.9 Adjusting camber on rear axle
  367
• 1.10 Adjusting toe at rear axle
  369
• 1.11 Adjusting front axle toe
  370
• 1.12 Wheel runout compensation
  371
• 1.13 Vehicle data sticker
  371
• 1.14 Checking maximum steering wheel angle
  371
• Steering
  373
• 1 Steering wheel
  373
• 1.1 Assembly overview – steering wheel
  373
• 1.2 Removing and installing steering wheel
  374
• 2 Steering column
  376
• 2.1 Assembly overview – steering column
  376
• 2.2 Checking steering column for damage
  377
• 2.3 Handling and transporting steering column
  378
• 2.4 Removing and installing steering column
  379
• 2.5 Removing and installing control unit for electronic steering column lock J764
  385
• 3 Steering rack
  388
• 3.1 Assembly overview – steering rack
  388
• 3.2 Removing and installing steering rack
  392
• 3.3 Removing and installing boot
  411
• 3.4 Removing and installing track rod
  414
• 3.5 Removing and installing track rod ball joint
  419
• 3.6 Repairing steering rack
  420
• 4 Sensors
  425
• 4.1 Removing and installing steering angle sender G85
  425